Modelling and analysis of selective assembly using Taguchi's loss function

An assembly is the integrative process of joining components to make a completed product. It brings together the upstream process of design, engineering and manufacturing processes. The functional performance of an assembled product and its manufacturing cost are directly affected by the individual...

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Bibliographic Details
Published in:International journal of production research 2008-08, Vol.46 (15), p.4309-4330
Main Authors: Kannan, S. M., Jeevanantham, A. K., Jayabalan, V.
Format: Article
Language:English
Subjects:
Applied sciences
Assembly clearance specification
Assembly lines
Average assembly loss per combination
Exact sciences and technology
Genetic algorithm
Genetic algorithms
Manufacturing
Mechanical engineering. Machine design
Production costs
Selective assembly
Studies
Taguchi methods
Taguchi's loss function
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Summary:An assembly is the integrative process of joining components to make a completed product. It brings together the upstream process of design, engineering and manufacturing processes. The functional performance of an assembled product and its manufacturing cost are directly affected by the individual component tolerances. But, the selective assembly method can achieve tight assembly tolerance through the components manufactured with wider tolerances. The components are segregated by the selective groups (bins) and mated according to a purposeful strategy rather than being at random, so that small clearances are obtained at the assembly level at lower manufacturing cost. In this paper, the effect of mean shift in the manufacturing of the mating components and the selection of number of groups for selective assembly are analysed. A new model is proposed based on their effect to obtain the minimum assembly clearance within the specification range. However, according to Taguchi's concept, manufacturing a product within the specification may not be sufficient. Rather, it must be manufactured to the target dimension. The concept of Taguchi's loss function is applied into the selective assembly method to evaluate the deviation from the mean. Subsequently, a genetic algorithm is used to obtain the best combination of selective groups with minimum clearance and least loss value within the clearance specification. The effect of the ratio between the mating part quality characteristic's dimensional distributions is also analysed in this paper.
ISSN:0020-7543
1366-588X
DOI:10.1080/00207540701241891