Off-Line Quality Control, Parameter Design, and the Taguchi Method

A Japanese ceramic tile manufacturer knew in 1953 that is more costly to control causes of manufacturing variations than to make a process insensitive to these variations

Raghu N. Kackar

2012

Key concepts

Scholarcy highlights

  • A Japanese ceramic tile manufacturer knew in 1953 that is more costly to control causes of manufacturing variations than to make a process insensitive to these variations
  • The Ina Tile Company knew that an uneven temperature distribution in the kiln caused variation in the size of the tiles
  • Since uneven temperature distribution was an assignable cause of variation, a process quality control approach would have increased manufacturing cost
  • Instead of controlling temperature distribution they tried to find a tile formulation that reduced the effect of uneven temperature distribution on the uniformity of tiles
  • The Ina Tile Company found a cost-effective method for reducing tile size variation caused by uneven temperature distribution in the kiln
  • The company found that increasing the content of lime in the tile formulation from 1% to 5% reduced the tile size variation by a factor of ten
  • This discovery was a breakthrough for the ceramic tile industry

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