I am senior academician retired from Government service. I have administrative and research experience appart from teaching job. Address: Coimbatore, Tamil Nadu, India
Thermal error modeling using the temperature data obtained from different thermal key points is o... more Thermal error modeling using the temperature data obtained from different thermal key points is one of the most basic requirements for thermal error compensation in CNC machining centers. Effective thermal error compensation relies on the accurate prediction of the time-variant thermal error during machining. The increase in number of thermal key points not only increases prediction noise in the thermal error model but is also very cost effective. Hence, optimization of thermal key points is essential for accurate prediction of thermal behaviour of machine tool. In this study, the thermal key points of horizontal feed drives of a vertical CNC machine are optimized based on sensitivity analysis. A non-linear statistical regression thermal error prediction model is developed by using the temperature data obtained from the optimized key points. Thermal errors predicted before and after sensitivity analysis of thermal key points using statistical model are presented. The developed model...
This paper examines the failure of shear pins that connect gearbox and generator in a wind turbin... more This paper examines the failure of shear pins that connect gearbox and generator in a wind turbine generator. Chemical and micro-structural together with hardness measurements have been performed to check any deviation in the material specification. The failure mechanism is analyzed by both visual and Scanning Electron Microscope (SEM) inspection on the fractured surface. Finite Element Analysis (FEA) of shear pin is carried out to determine the root cause for its failure. The neck diameter of shear pin is optimized for the safe operation of the wind turbine. It is inferred from the observations based on fractography study on the fractured surface of the shear pins that the misalignment between the driving and the driven elements in the wind turbine leads to low cyclic fatigue growth.
In the recent past, Six Sigma approach had been the methodology of choice for achieving quality a... more In the recent past, Six Sigma approach had been the methodology of choice for achieving quality and productivity through streamlined business practices that would eventually delight customers. Though Six Sigma had been expanded to several industrial sectors presently, only few research attempts have been noticed to examine the successful implementation of the method in the organisations. Despite the fact that organisations achieve benefits from Six Sigma implementations, such benefits are not sustainable until Six Sigma programme gets incorporated with its critical success factors while implementing to improve product or service quality. From a comprehensive literature review it has been understood that quality function deployment and the theory of inventive problem solving could be integrated with Six Sigma to develop an extended model of Six Sigma to incorporate some of its critical success factors. Accordingly, a model named 'total performance excellence' (TPE) is designed and presented in this article.
Six Sigma is one of the most widely used methodologies in many organisations for improving the qu... more Six Sigma is one of the most widely used methodologies in many organisations for improving the quality of process/product to enhance customer satisfaction and company revenue. A detailed literature review discloses that the project selection is an area of extreme importance for assuring the success of Six Sigma implementation, but that has been less researched in the past. This research paper aims to develop a project selection method by combining quality function deployment and Six Sigma to assist the organisations as well as Six Sigma consultants for selecting right project. A real-time case study from an Indian small- and medium-sized enterprise is explored in this paper to see the sights of the proposed methodology.
Six Sigma is regarded as a well-structured methodology for improving the quality of processes and... more Six Sigma is regarded as a well-structured methodology for improving the quality of processes and products. It helps achieve the company’s strategic goal through the effective use of project-driven approach. As Six Sigma is a project-driven methodology, it is essential to prioritise projects which provide maximum financial benefits to the organisation. Generating and prioritising the critical Six Sigma projects, however, are real challenges in practice. A detailed literature review on Six Sigma research reveals that project selection is an area of extreme importance for assuring success of Six Sigma implementation, but that has been less researched in the past. This paper provides both academics and practitioners with a useful framework for pursuing rigorous Six Sigma project selection research through snapshot review of published literatures.
This research study proposes an innovative analysis for controlling the defects in aluminium die... more This research study proposes an innovative analysis for controlling the defects in aluminium die casting business. Six Sigma DMAIC (define, measure, analyse, improve, control) methodology is used to analyse the problem. Process validation is done with Taguchi DOE and ANOVA analysis at 95% confidence showed that the metal temperature is the vital process parameter causing defects. Confirmation experiment at optimum process parameter level showed defect level reduced from 17.22% to 4.8%. Since aluminium die casting is one of the most widely used process for producing automobile components, this study provides a methodology for improving the die casting business excellence.
Six Sigma has become a popular approach in many organizations today to sustain competitive advant... more Six Sigma has become a popular approach in many organizations today to sustain competitive advantage. Though the benefits of Six Sigma method to organizations are great, challenges and realities in successful implementing are immense. Many Six Sigma literatures have been published in which success stories were discussed primarily. Few literatures have addressed the challenges of Six Sigma practice based on the lessons learned during implementation. This paper attempts to fortify the common Six Sigma approach by mapping the organizational hierarchy with implementation process. The challenges associated with each level of the organizational hierarchy are revealed and key factors to success are recommended for Six Sigma excellence in dynamic 21st century.
This paper examines failure of helical gear in speed increasing gearbox used in the wind turbine ... more This paper examines failure of helical gear in speed increasing gearbox used in the wind turbine generator (WTG). In addition, an attempt has been made to get suitable gear micro-geometry such as pressure angle and tip relief to minimize the gear failure in the wind turbines. As the gear trains in the wind turbine gearbox is prearranged with higher speed ratio and the gearboxes experience shock load due to atmospheric turbulence, gust wind speed, non-synchronization of pitching, frequent grid drops and failure of braking, the gear failure occurs either in the intermediate or high speed stage pinion. KISS soft gear calculation software was used to determine the gear specifications and analysis is carried out in ANSYS software version.11.0 for the existing and the proposed gear to evaluate the performance of bending stress tooth deflection and stiffness. The main objective of this research study is to propose suitable gear micro-geometry that is tip relief and pressure angle blend for increasing tooth strength of the helical gear used in the wind turbine for trouble free operation.
This paper examines the failure of shear pins that connect gearbox and generator in a wind turbin... more This paper examines the failure of shear pins that connect gearbox and generator in a wind turbine generator. Chemical and micro-structural together with hardness measurements have been performed to check any deviation in the material specification. The failure mechanism is analyzed by both visual and Scanning Electron Microscope (SEM) inspection on the fractured surface. Finite Element Analysis (FEA) of shear pin is carried out to determine the root cause for its failure. The neck diameter of shear pin is optimized for the safe operation of the wind turbine. It is inferred from the observations based on fractography study on the fractured surface of the shear pins that the misalignment between the driving and the driven elements in the wind turbine leads to low cyclic fatigue growth.
In this study, the characteristics of low specific speed centrifugal water pump are presented. Th... more In this study, the characteristics of low specific speed centrifugal water pump are presented. The characteristics are evaluated by studying the relationships among the impeller eye diameter, vane exit angle and width of the blade at exit. As these pumps are of Non-positive type, the discharge is greatly affected by any resistance to flow, outlet conditions and design parameters of impeller and casing. Therefore it is necessary to find out the design parameters and working conditions that yield optimal output and maximum efficiency with lowest power consumption. This paper is devoted to the performance evaluation of a centrifugal pump for the given specification. Different pump models are developed by varying critical design parameters to different levels. Response surface method is used for Experimental Design (DoE). Computational Fluid Dynamics (CFD) analysis is carried out on the developed models to predict the performance virtually and to verify with the experimental result of the pump. Optimal pump design is formulated using Response surface method. The objective functions are defined as the total head and the total efficiency at the design flow-rate.
This paper illustrates the improvement in the performance of a centrifugal pump by modifying impe... more This paper illustrates the improvement in the performance of a centrifugal pump by modifying impeller design specifications via response surface methodology (RSM) complemented with computational fluid dynamics (CFD) simulations. Impeller geometry is varied at the best efficiency point (BEP) to get hold of the performance of the pump. The pump characteristics are evaluated by studying the impeller eye diameter, vane exit angle, and width of impeller blade at exit. Different pump models were analyzed by modifying the critical design parameters via central composite design. CFD analysis is carried out for the developed models to predict the performance of the pump and experimental studies were conducted to validate the CFD. Conformation experiments were performed to verify the optimal design specifications. Good agreements between the predicted and actual values of responses have been observed. The RSM- and CFD-based optimized impeller parameters yield an increase in total head from 39.66m to 41.72m and the power consumption is minimized from 432.17W to 366.95W at BEP.
This paper describes a model for Customer care management in an automotive service industry. Desi... more This paper describes a model for Customer care management in an automotive service industry. Design / methodology / approach – Customer care management (CCM) model is developed using TQM techniques, Quality Function Deployment (QFD) and Six Sigma. The matrix structure in QFD is used to transform customer complaints into Critical-to-Quality (CTQ) parameters. By using Six Sigma DMAIC approach, the customer complaint parameters are analyzed for improvement. Findings – The application of CCM model in an automobile service industry has determined that the workload planning is the chronic problem for customer complaint. Further analysis through this model leads to restructuring of existing workload planning practice through a set of algorithms. Research limitations/implications – CCM model lacks to accommodate the effect of relationship between rectification factors. Also competitor technical contemplation is not possible in this model. Originality/value – Customer is the focal point and early response to their complaint is the key to success of every business. This paper has developed a structured complaint management practice which warrants the timely response to customer complaints and speedy resolution for survival in today’s customer driven market.
In High Speed Machining Processes, a major quality related output is surface roughness of the mac... more In High Speed Machining Processes, a major quality related output is surface roughness of the machined surfaces. Machining of the difficult-to-cut materials under high speed machining conditions results a drastic decrease in tool-life. Huge cutting force and higher cut edge temperature leads to poor surface finish. An attempt has been made in this paper to study the influence of cutting parameters on surface integrity of Inconel 718 nickel based super alloy under cryogenic cooling conditions during high speed machining. Experiments were carried out using Taguchi‟s L18 mixed orthogonal array based quality design concept to arrive the best optimal parametric combination by varying the cutting speed, feed, depth of cut, tool nose radius, air / LN2 pressure and the head level of LN2 in the cryocan. Analysis of variance (ANOVA) was done to find out the significance of the machining parameters while machining Inconel 718. Confirmation experiments were conducted to validate the experimental investigation.
This research study proposes an innovative analysis for controlling the defects in aluminium die ... more This research study proposes an innovative analysis for controlling the defects in aluminium die casting industry. In this analysis, casting process of a two-stroke engine oil pump body is concentrated. The component selected has often rejected due to blow hole defects. Six Sigma, the zero defect approach, is used in this study. Define measure, analyse, improve and control (DMAIC) problem solving methodology is applied for problem analysis. Taguchi’s experimental design is used for process validation and improvement. The confirmation experiment showed that the rejection rate was reduced to 4.8% from 17.22%. The application of Six Sigma program with Taguchi technique has developed an innovative cost effective methodology for controlling defects in die casting process in less experimental time.
The objective of this research paper is to examine the influence of design modifications in drum ... more The objective of this research paper is to examine the influence of design modifications in drum cup made of aluminum metal matrix composites with inclusion of fly ash particles as materials for the brake drum. Sequential coupled field analysis was performed to find out the brake drum firmness and also to judge the heat dissipation in wheel cub assembly. The structural and thermal analysis was carried out using Finite Element Technique for the custom-made brake drum made of different materials between the threshold temperature of inside the brake drum and tube temperature. Stresses and deflections are measured for the existing design and modified design. The study infers that the Al-Metal Matrix Composite using fly ash as reinforcement for drum model encompass fin at circular periphery with castellated outer surface offers efficient braking systems rather than the cast iron model of similar design.
Statistical-based Analysis of Thermally Induced Errors in Computer Numerical Control (CNC) Machin... more Statistical-based Analysis of Thermally Induced Errors in Computer Numerical Control (CNC) Machining Center
Variation in product performance can be seen as
a design failure. The fundamental principle of ro... more Variation in product performance can be seen as a design failure. The fundamental principle of robust design proposed by Taguchi is to improve the quality of a product by minimizing the effect of causes of variation, without totally eliminating the causes. A method of robust design is briefly explained and its application is demonstrated with the help of a case study from Roots Industries Ltd., Coimbatore. This paper describes how the inherent modeling of product and process requirements in key characteristics (KCs) can be used to express and capture the product design intent. KCs are those features which significantly affect product function and performance, or occur when there is variation. A prototype software program (VRM Tool) was developed to house all the critical design data for process optimization and its eventual reuse. We establish a systematic process of identifying, assessing and mitigating risk in the early stage of design for a Windtone class of automobile electric horn, using robust design concept. The results suggest that the proposed robust design method is an efficient, disciplined approach that can assist a product delivery team in designing for a better functional performance and improved reliability of the entire system.
This paper discusses empirical model development to predict surface roughness of
components machi... more This paper discusses empirical model development to predict surface roughness of components machined in CNC turning centre via parametric design concept. Process variables selected in parametric design are spindle speed, feed rate, cutter nose radius and depth of cut. Non linear regression analysis with logarithmic data transformation is used for the model development. The near optimum combination of machining parameters for the best surface roughness is achieved using Design of Experiments. Confirmation trial runs are conducted to get foolproof results. The regression model is validated with a case study.
It is critical for an industrial organisation to strike a balance between what is
defined and the... more It is critical for an industrial organisation to strike a balance between what is defined and the way to achieve it at the least cost, so as to maintain competitiveness. Also, considerable resources, in terms of time, cost, material, quality, etc., are spent before a valid inference is taken. The Taguchi method is a technique that addresses said industrial needs, enabling the designer to find the optimum combination of control parameters to make the response insensitive to noise factors. This research paper discusses parameter optimisation of the planer cam mechanism via computer-based models, at the start of the design stage, by Taguchi's Orthogonal Array (OA) based Design of Experiments (DOE) to understand how the variation in product specifications affect the system performance.
Taguchi parameter design research methodology allows one to make products or processes robust to ... more Taguchi parameter design research methodology allows one to make products or processes robust to uncontrollable noise factors and will also reduce the number of experiments to be carried out to arrive an optimized system. The main objective of this work is to study the various operating parameters of diesel engine to propose modified engine parameter (optimum) settings for reduction in NO X , HC, CO and smoke concentrations simultaneously in diesel emission by applying Taguchi parameter design concept. Taguchi L 18 (2 1 ×3 7 ) quality design concept mixed orthogonal array has been used to determine the S/N ratio (dB), analysis of variance (ANOVA) and F 0 test values for recognizing most significant engine operating parameters that influence exhaust emission. The experimental results give an idea about how the variations in engine settings like nozzle spray holes, piston-to-head clearance, nozzle protrusion, injection control pressure, start of injection timing and swirl level alter the pollutant (NO X, HC, CO and smoke) intensity in emission. Considering these significant engine-operating parameters, verification of the improvement in the quality characteristics for emission reduction has been done through confirmation test with reference to the chosen initial or reference parameter settings. These confirmation test results prove that the optimal combination of diesel engine parameters obtained from the investigation reducing the pollutant levels in exhaust emission in reality.
Thermal error modeling using the temperature data obtained from different thermal key points is o... more Thermal error modeling using the temperature data obtained from different thermal key points is one of the most basic requirements for thermal error compensation in CNC machining centers. Effective thermal error compensation relies on the accurate prediction of the time-variant thermal error during machining. The increase in number of thermal key points not only increases prediction noise in the thermal error model but is also very cost effective. Hence, optimization of thermal key points is essential for accurate prediction of thermal behaviour of machine tool. In this study, the thermal key points of horizontal feed drives of a vertical CNC machine are optimized based on sensitivity analysis. A non-linear statistical regression thermal error prediction model is developed by using the temperature data obtained from the optimized key points. Thermal errors predicted before and after sensitivity analysis of thermal key points using statistical model are presented. The developed model...
This paper examines the failure of shear pins that connect gearbox and generator in a wind turbin... more This paper examines the failure of shear pins that connect gearbox and generator in a wind turbine generator. Chemical and micro-structural together with hardness measurements have been performed to check any deviation in the material specification. The failure mechanism is analyzed by both visual and Scanning Electron Microscope (SEM) inspection on the fractured surface. Finite Element Analysis (FEA) of shear pin is carried out to determine the root cause for its failure. The neck diameter of shear pin is optimized for the safe operation of the wind turbine. It is inferred from the observations based on fractography study on the fractured surface of the shear pins that the misalignment between the driving and the driven elements in the wind turbine leads to low cyclic fatigue growth.
In the recent past, Six Sigma approach had been the methodology of choice for achieving quality a... more In the recent past, Six Sigma approach had been the methodology of choice for achieving quality and productivity through streamlined business practices that would eventually delight customers. Though Six Sigma had been expanded to several industrial sectors presently, only few research attempts have been noticed to examine the successful implementation of the method in the organisations. Despite the fact that organisations achieve benefits from Six Sigma implementations, such benefits are not sustainable until Six Sigma programme gets incorporated with its critical success factors while implementing to improve product or service quality. From a comprehensive literature review it has been understood that quality function deployment and the theory of inventive problem solving could be integrated with Six Sigma to develop an extended model of Six Sigma to incorporate some of its critical success factors. Accordingly, a model named 'total performance excellence' (TPE) is designed and presented in this article.
Six Sigma is one of the most widely used methodologies in many organisations for improving the qu... more Six Sigma is one of the most widely used methodologies in many organisations for improving the quality of process/product to enhance customer satisfaction and company revenue. A detailed literature review discloses that the project selection is an area of extreme importance for assuring the success of Six Sigma implementation, but that has been less researched in the past. This research paper aims to develop a project selection method by combining quality function deployment and Six Sigma to assist the organisations as well as Six Sigma consultants for selecting right project. A real-time case study from an Indian small- and medium-sized enterprise is explored in this paper to see the sights of the proposed methodology.
Six Sigma is regarded as a well-structured methodology for improving the quality of processes and... more Six Sigma is regarded as a well-structured methodology for improving the quality of processes and products. It helps achieve the company’s strategic goal through the effective use of project-driven approach. As Six Sigma is a project-driven methodology, it is essential to prioritise projects which provide maximum financial benefits to the organisation. Generating and prioritising the critical Six Sigma projects, however, are real challenges in practice. A detailed literature review on Six Sigma research reveals that project selection is an area of extreme importance for assuring success of Six Sigma implementation, but that has been less researched in the past. This paper provides both academics and practitioners with a useful framework for pursuing rigorous Six Sigma project selection research through snapshot review of published literatures.
This research study proposes an innovative analysis for controlling the defects in aluminium die... more This research study proposes an innovative analysis for controlling the defects in aluminium die casting business. Six Sigma DMAIC (define, measure, analyse, improve, control) methodology is used to analyse the problem. Process validation is done with Taguchi DOE and ANOVA analysis at 95% confidence showed that the metal temperature is the vital process parameter causing defects. Confirmation experiment at optimum process parameter level showed defect level reduced from 17.22% to 4.8%. Since aluminium die casting is one of the most widely used process for producing automobile components, this study provides a methodology for improving the die casting business excellence.
Six Sigma has become a popular approach in many organizations today to sustain competitive advant... more Six Sigma has become a popular approach in many organizations today to sustain competitive advantage. Though the benefits of Six Sigma method to organizations are great, challenges and realities in successful implementing are immense. Many Six Sigma literatures have been published in which success stories were discussed primarily. Few literatures have addressed the challenges of Six Sigma practice based on the lessons learned during implementation. This paper attempts to fortify the common Six Sigma approach by mapping the organizational hierarchy with implementation process. The challenges associated with each level of the organizational hierarchy are revealed and key factors to success are recommended for Six Sigma excellence in dynamic 21st century.
This paper examines failure of helical gear in speed increasing gearbox used in the wind turbine ... more This paper examines failure of helical gear in speed increasing gearbox used in the wind turbine generator (WTG). In addition, an attempt has been made to get suitable gear micro-geometry such as pressure angle and tip relief to minimize the gear failure in the wind turbines. As the gear trains in the wind turbine gearbox is prearranged with higher speed ratio and the gearboxes experience shock load due to atmospheric turbulence, gust wind speed, non-synchronization of pitching, frequent grid drops and failure of braking, the gear failure occurs either in the intermediate or high speed stage pinion. KISS soft gear calculation software was used to determine the gear specifications and analysis is carried out in ANSYS software version.11.0 for the existing and the proposed gear to evaluate the performance of bending stress tooth deflection and stiffness. The main objective of this research study is to propose suitable gear micro-geometry that is tip relief and pressure angle blend for increasing tooth strength of the helical gear used in the wind turbine for trouble free operation.
This paper examines the failure of shear pins that connect gearbox and generator in a wind turbin... more This paper examines the failure of shear pins that connect gearbox and generator in a wind turbine generator. Chemical and micro-structural together with hardness measurements have been performed to check any deviation in the material specification. The failure mechanism is analyzed by both visual and Scanning Electron Microscope (SEM) inspection on the fractured surface. Finite Element Analysis (FEA) of shear pin is carried out to determine the root cause for its failure. The neck diameter of shear pin is optimized for the safe operation of the wind turbine. It is inferred from the observations based on fractography study on the fractured surface of the shear pins that the misalignment between the driving and the driven elements in the wind turbine leads to low cyclic fatigue growth.
In this study, the characteristics of low specific speed centrifugal water pump are presented. Th... more In this study, the characteristics of low specific speed centrifugal water pump are presented. The characteristics are evaluated by studying the relationships among the impeller eye diameter, vane exit angle and width of the blade at exit. As these pumps are of Non-positive type, the discharge is greatly affected by any resistance to flow, outlet conditions and design parameters of impeller and casing. Therefore it is necessary to find out the design parameters and working conditions that yield optimal output and maximum efficiency with lowest power consumption. This paper is devoted to the performance evaluation of a centrifugal pump for the given specification. Different pump models are developed by varying critical design parameters to different levels. Response surface method is used for Experimental Design (DoE). Computational Fluid Dynamics (CFD) analysis is carried out on the developed models to predict the performance virtually and to verify with the experimental result of the pump. Optimal pump design is formulated using Response surface method. The objective functions are defined as the total head and the total efficiency at the design flow-rate.
This paper illustrates the improvement in the performance of a centrifugal pump by modifying impe... more This paper illustrates the improvement in the performance of a centrifugal pump by modifying impeller design specifications via response surface methodology (RSM) complemented with computational fluid dynamics (CFD) simulations. Impeller geometry is varied at the best efficiency point (BEP) to get hold of the performance of the pump. The pump characteristics are evaluated by studying the impeller eye diameter, vane exit angle, and width of impeller blade at exit. Different pump models were analyzed by modifying the critical design parameters via central composite design. CFD analysis is carried out for the developed models to predict the performance of the pump and experimental studies were conducted to validate the CFD. Conformation experiments were performed to verify the optimal design specifications. Good agreements between the predicted and actual values of responses have been observed. The RSM- and CFD-based optimized impeller parameters yield an increase in total head from 39.66m to 41.72m and the power consumption is minimized from 432.17W to 366.95W at BEP.
This paper describes a model for Customer care management in an automotive service industry. Desi... more This paper describes a model for Customer care management in an automotive service industry. Design / methodology / approach – Customer care management (CCM) model is developed using TQM techniques, Quality Function Deployment (QFD) and Six Sigma. The matrix structure in QFD is used to transform customer complaints into Critical-to-Quality (CTQ) parameters. By using Six Sigma DMAIC approach, the customer complaint parameters are analyzed for improvement. Findings – The application of CCM model in an automobile service industry has determined that the workload planning is the chronic problem for customer complaint. Further analysis through this model leads to restructuring of existing workload planning practice through a set of algorithms. Research limitations/implications – CCM model lacks to accommodate the effect of relationship between rectification factors. Also competitor technical contemplation is not possible in this model. Originality/value – Customer is the focal point and early response to their complaint is the key to success of every business. This paper has developed a structured complaint management practice which warrants the timely response to customer complaints and speedy resolution for survival in today’s customer driven market.
In High Speed Machining Processes, a major quality related output is surface roughness of the mac... more In High Speed Machining Processes, a major quality related output is surface roughness of the machined surfaces. Machining of the difficult-to-cut materials under high speed machining conditions results a drastic decrease in tool-life. Huge cutting force and higher cut edge temperature leads to poor surface finish. An attempt has been made in this paper to study the influence of cutting parameters on surface integrity of Inconel 718 nickel based super alloy under cryogenic cooling conditions during high speed machining. Experiments were carried out using Taguchi‟s L18 mixed orthogonal array based quality design concept to arrive the best optimal parametric combination by varying the cutting speed, feed, depth of cut, tool nose radius, air / LN2 pressure and the head level of LN2 in the cryocan. Analysis of variance (ANOVA) was done to find out the significance of the machining parameters while machining Inconel 718. Confirmation experiments were conducted to validate the experimental investigation.
This research study proposes an innovative analysis for controlling the defects in aluminium die ... more This research study proposes an innovative analysis for controlling the defects in aluminium die casting industry. In this analysis, casting process of a two-stroke engine oil pump body is concentrated. The component selected has often rejected due to blow hole defects. Six Sigma, the zero defect approach, is used in this study. Define measure, analyse, improve and control (DMAIC) problem solving methodology is applied for problem analysis. Taguchi’s experimental design is used for process validation and improvement. The confirmation experiment showed that the rejection rate was reduced to 4.8% from 17.22%. The application of Six Sigma program with Taguchi technique has developed an innovative cost effective methodology for controlling defects in die casting process in less experimental time.
The objective of this research paper is to examine the influence of design modifications in drum ... more The objective of this research paper is to examine the influence of design modifications in drum cup made of aluminum metal matrix composites with inclusion of fly ash particles as materials for the brake drum. Sequential coupled field analysis was performed to find out the brake drum firmness and also to judge the heat dissipation in wheel cub assembly. The structural and thermal analysis was carried out using Finite Element Technique for the custom-made brake drum made of different materials between the threshold temperature of inside the brake drum and tube temperature. Stresses and deflections are measured for the existing design and modified design. The study infers that the Al-Metal Matrix Composite using fly ash as reinforcement for drum model encompass fin at circular periphery with castellated outer surface offers efficient braking systems rather than the cast iron model of similar design.
Statistical-based Analysis of Thermally Induced Errors in Computer Numerical Control (CNC) Machin... more Statistical-based Analysis of Thermally Induced Errors in Computer Numerical Control (CNC) Machining Center
Variation in product performance can be seen as
a design failure. The fundamental principle of ro... more Variation in product performance can be seen as a design failure. The fundamental principle of robust design proposed by Taguchi is to improve the quality of a product by minimizing the effect of causes of variation, without totally eliminating the causes. A method of robust design is briefly explained and its application is demonstrated with the help of a case study from Roots Industries Ltd., Coimbatore. This paper describes how the inherent modeling of product and process requirements in key characteristics (KCs) can be used to express and capture the product design intent. KCs are those features which significantly affect product function and performance, or occur when there is variation. A prototype software program (VRM Tool) was developed to house all the critical design data for process optimization and its eventual reuse. We establish a systematic process of identifying, assessing and mitigating risk in the early stage of design for a Windtone class of automobile electric horn, using robust design concept. The results suggest that the proposed robust design method is an efficient, disciplined approach that can assist a product delivery team in designing for a better functional performance and improved reliability of the entire system.
This paper discusses empirical model development to predict surface roughness of
components machi... more This paper discusses empirical model development to predict surface roughness of components machined in CNC turning centre via parametric design concept. Process variables selected in parametric design are spindle speed, feed rate, cutter nose radius and depth of cut. Non linear regression analysis with logarithmic data transformation is used for the model development. The near optimum combination of machining parameters for the best surface roughness is achieved using Design of Experiments. Confirmation trial runs are conducted to get foolproof results. The regression model is validated with a case study.
It is critical for an industrial organisation to strike a balance between what is
defined and the... more It is critical for an industrial organisation to strike a balance between what is defined and the way to achieve it at the least cost, so as to maintain competitiveness. Also, considerable resources, in terms of time, cost, material, quality, etc., are spent before a valid inference is taken. The Taguchi method is a technique that addresses said industrial needs, enabling the designer to find the optimum combination of control parameters to make the response insensitive to noise factors. This research paper discusses parameter optimisation of the planer cam mechanism via computer-based models, at the start of the design stage, by Taguchi's Orthogonal Array (OA) based Design of Experiments (DOE) to understand how the variation in product specifications affect the system performance.
Taguchi parameter design research methodology allows one to make products or processes robust to ... more Taguchi parameter design research methodology allows one to make products or processes robust to uncontrollable noise factors and will also reduce the number of experiments to be carried out to arrive an optimized system. The main objective of this work is to study the various operating parameters of diesel engine to propose modified engine parameter (optimum) settings for reduction in NO X , HC, CO and smoke concentrations simultaneously in diesel emission by applying Taguchi parameter design concept. Taguchi L 18 (2 1 ×3 7 ) quality design concept mixed orthogonal array has been used to determine the S/N ratio (dB), analysis of variance (ANOVA) and F 0 test values for recognizing most significant engine operating parameters that influence exhaust emission. The experimental results give an idea about how the variations in engine settings like nozzle spray holes, piston-to-head clearance, nozzle protrusion, injection control pressure, start of injection timing and swirl level alter the pollutant (NO X, HC, CO and smoke) intensity in emission. Considering these significant engine-operating parameters, verification of the improvement in the quality characteristics for emission reduction has been done through confirmation test with reference to the chosen initial or reference parameter settings. These confirmation test results prove that the optimal combination of diesel engine parameters obtained from the investigation reducing the pollutant levels in exhaust emission in reality.
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Papers by Mnj Nataraj
are analyzed for improvement. Findings – The application of CCM model in an automobile service industry has determined
that the workload planning is the chronic problem for customer complaint. Further analysis through this model
leads to restructuring of existing workload planning practice through a set of algorithms. Research limitations/implications
– CCM model lacks to accommodate the effect of relationship between rectification factors. Also competitor
technical contemplation is not possible in this model. Originality/value – Customer is the focal point and early response
to their complaint is the key to success of every business. This paper has developed a structured complaint management practice which warrants the timely response to customer complaints and speedy resolution for survival in today’s customer driven market.
a design failure. The fundamental principle of robust design
proposed by Taguchi is to improve the quality of a product
by minimizing the effect of causes of variation, without totally
eliminating the causes. A method of robust design is
briefly explained and its application is demonstrated with the
help of a case study from Roots Industries Ltd., Coimbatore.
This paper describes how the inherent modeling of product
and process requirements in key characteristics (KCs) can be
used to express and capture the product design intent. KCs
are those features which significantly affect product function
and performance, or occur when there is variation. A prototype
software program (VRM Tool) was developed to house
all the critical design data for process optimization and its
eventual reuse. We establish a systematic process of identifying,
assessing and mitigating risk in the early stage of design
for a Windtone class of automobile electric horn, using robust
design concept. The results suggest that the proposed robust
design method is an efficient, disciplined approach that
can assist a product delivery team in designing for a better
functional performance and improved reliability of the entire
system.
components machined in CNC turning centre via parametric design concept. Process variables
selected in parametric design are spindle speed, feed rate, cutter nose radius and depth of cut. Non
linear regression analysis with logarithmic data transformation is used for the model development.
The near optimum combination of machining parameters for the best surface roughness is achieved
using Design of Experiments. Confirmation trial runs are conducted to get foolproof results. The
regression model is validated with a case study.
defined and the way to achieve it at the least cost, so as to maintain competitiveness.
Also, considerable resources, in terms of time, cost, material, quality, etc., are spent
before a valid inference is taken. The Taguchi method is a technique that addresses said
industrial needs, enabling the designer to find the optimum combination of control
parameters to make the response insensitive to noise factors. This research paper
discusses parameter optimisation of the planer cam mechanism via computer-based
models, at the start of the design stage, by Taguchi's Orthogonal Array (OA) based
Design of Experiments (DOE) to understand how the variation in product specifications
affect the system performance.
are analyzed for improvement. Findings – The application of CCM model in an automobile service industry has determined
that the workload planning is the chronic problem for customer complaint. Further analysis through this model
leads to restructuring of existing workload planning practice through a set of algorithms. Research limitations/implications
– CCM model lacks to accommodate the effect of relationship between rectification factors. Also competitor
technical contemplation is not possible in this model. Originality/value – Customer is the focal point and early response
to their complaint is the key to success of every business. This paper has developed a structured complaint management practice which warrants the timely response to customer complaints and speedy resolution for survival in today’s customer driven market.
a design failure. The fundamental principle of robust design
proposed by Taguchi is to improve the quality of a product
by minimizing the effect of causes of variation, without totally
eliminating the causes. A method of robust design is
briefly explained and its application is demonstrated with the
help of a case study from Roots Industries Ltd., Coimbatore.
This paper describes how the inherent modeling of product
and process requirements in key characteristics (KCs) can be
used to express and capture the product design intent. KCs
are those features which significantly affect product function
and performance, or occur when there is variation. A prototype
software program (VRM Tool) was developed to house
all the critical design data for process optimization and its
eventual reuse. We establish a systematic process of identifying,
assessing and mitigating risk in the early stage of design
for a Windtone class of automobile electric horn, using robust
design concept. The results suggest that the proposed robust
design method is an efficient, disciplined approach that
can assist a product delivery team in designing for a better
functional performance and improved reliability of the entire
system.
components machined in CNC turning centre via parametric design concept. Process variables
selected in parametric design are spindle speed, feed rate, cutter nose radius and depth of cut. Non
linear regression analysis with logarithmic data transformation is used for the model development.
The near optimum combination of machining parameters for the best surface roughness is achieved
using Design of Experiments. Confirmation trial runs are conducted to get foolproof results. The
regression model is validated with a case study.
defined and the way to achieve it at the least cost, so as to maintain competitiveness.
Also, considerable resources, in terms of time, cost, material, quality, etc., are spent
before a valid inference is taken. The Taguchi method is a technique that addresses said
industrial needs, enabling the designer to find the optimum combination of control
parameters to make the response insensitive to noise factors. This research paper
discusses parameter optimisation of the planer cam mechanism via computer-based
models, at the start of the design stage, by Taguchi's Orthogonal Array (OA) based
Design of Experiments (DOE) to understand how the variation in product specifications
affect the system performance.