Constrained Response Surface Optimisation and Taguchi Methods for Precisely Atomising Spraying Process

Abstract

This research presents a development of a design of experiment technique for quality improvement in automotive manufacturing industrial. The quality of interest is the colour shade, one of the key feature and exterior appearance for the vehicles. With low percentage of first time quality, the manufacturer has spent a lot of cost for repaired works as well as the longer production time. To permanently dissolve such problem, the precisely spraying condition should be optimized. Therefore, this work will apply the full factorial design, the multiple regression, the constrained response surface optimization methods or CRSOM, and Taguchi’s method to investigate the significant factors and to determine the optimum factor level in order to improve the quality of paint shop. Firstly, 2κ full factorial was employed to study the effect of five factors including the paint flow rate at robot setting, the paint levelling agent, the paint pigment, the additive slow solvent, and non volatile solid at spraying of atomizing spraying machine. The response values of colour shade at 15 and 45 degrees were measured using spectrophotometer. Then the regression models of colour shade at both degrees were developed from the significant factors affecting each response. Consequently, both regression models were placed into the form of linear programming to maximize the colour shade subjected to 3 main factors including the pigment, the additive solvent and the flow rate. Finally, Taguchi’s method was applied to determine the proper level of key variable factors to achieve the mean value target of colour shade. The factor of non volatile solid was found to be one more additional factor at this stage. Consequently, the proper level of all factors from both experiment design methods were used to set a confirmation experiment. It was found that the colour shades, both visual at 15 and 45 angel of measurement degrees of spectrophotometer, were nearly closed to the target and the defective at quality gate was also reduced from 0.35 WDPV to 0.10 WDPV. This reveals that the objective of this research is met and this procedure can be used as quality improvement guidance for paint shop of automotive vehicle.