OPTIMIZATION OF PROCESS PARAMETER BY USING SIMULATION- TAGUCHI APPROACH: A CASE OF HABTAMU SILA PLASTIC FACTORY IN HAWASSA CITY

Abstract

The control of integrated manufacturing systems is usually complex. One approach that can accommodate such complexity is modeling the manufacturing processes on a computer. The primary objective of any company is to produce products with low cost. Process parameter optimization in a cost bases optimal selection of extrusion rate, setup time, feed rate, and capacity of the loading station. Besides, the use of computer simulation have been proposed and executed to tackle the issues of manufacturing cost reduction. A simulation model is an instrument in analyzing execution. Even though next studies of the outcomes of simulation can be used for investigation of design of experiment, investigation of optimum manufacturing process parameter to reduce the cost of manufacturing. Therefore, this paper deals with the optimization of process parameters in a manufacturing system to minimize the Unit Manufacturing Cost (UMC) of Un-plasticized Poly Vinyl Chloride pipes using a combined Simulation–Taguchi approach. With the new perspectives of integrated modeling, the study contributes to the body of knowledge, which also opens a new outlook for further studies. Taguchi design of experiment is useful for managing this study and L27 orthogonal array was selected. Thus, a significant factor along with their optimum combination is using Taguchi techniques to arrive at the least manufacturing cost. The results show that these methods can be useful in reducing the number of experimental trials needed to determine the best operating parameters. The results show that key parameters for optimum performance of the system are feed rate in to the hopper and the optimization of the extruder; The predicted unit cost of manufacturing the selected pipe model is 220 Birr and thus costs decreased by 28.8%., because the utilization of the machine increased by 33%, 34.6% for the worker from the actual performance. As part of the general outcome of this study, Taguchi method was helpful for reduction of unit manufacturing cost either at the product development or at process design stage and identifying optimum control parameter combinations