Using mixed goal programming to optimize performance of extrusion process for multiple responses of irrigation pipes

Abstract

The performance of the polyethylene extrusion process used in the plastic industry was optimized using mixed goal programming. Four responses, the roll weight, production cycle time, distance between emitters, and thickness, are crucial. After a combination of initial factor settings was determined, individual and moving range control charts were established for each response. Two-phase optimization was implemented using L18 and L9 arrays for conducting experiments. A two-phase fuzzy goal programming model was formulated and employed to determine the combination of optimal factor settings, which was used to perform experiments. The results showed a significant reduction in the average production time from 13.0 to 11.316 min. Moreover, the average respective relative percentages of variability reduction for the roll weight, production cycle time, distance between emitters, and thickness were 48.547%, 49.048%, 47.174%, and 63.704%, respectively, and the corresponding estimated process capability indices for the combination of initial (optimal) factor settings were 0.202 (1.440), 0.330 (0.914), and 0.460 (1.456). Such improvement results in significant reduction in quality costs.