APPLICATION OF TAGUCHI METHODOLOGY FOR PARAMETER SETTING OPTIMIZATION OF INJECTION MOLDING TO REDUCE BENDING DEFECT

Abstract

In mid-June in 2020, PT. BRB INDONESIA received 97 customers complaints about the bending of accessories in the form of cameras on the FBD70 product. Therefore, as many as 10,000 pieces of product cause of various types of defect in the record. Lack of optimization of parameter settings causes instability of items produced by injection molding machines and allows more complaints from customers. Therefore, further research is needed regarding the optimization of parameter settings in the use of injection molding. Taguchi Method in Design of Experiment (DOE) is a very appropriate method to determine the optimization of parameter settings in the injection molding process. Taguchi Method is a statistical technique used to study multiple variables (also called parameters) simultaneously. For the experiment results, the optimum combination setting level are cooling time at level 1 (10 sec), injection pressure at level 3 (105 bar), injection speed at level 1 (12 cm/s). By using the optimal combination, the variations can be reduced and the deviation on Pin A of FBD70 bending measurement can be eliminated. The confirmation result is able to produce pin A of FBD70 with bending measurement average from 0.9 as the initial result to 3.43 which is closer to 3.4 as the bending tolerance in product specification. S/N Ratio using the optimum parameter setting is increased from 17.04 dB to 39.5 dB. The Taguchi Loss Function is able to reduce the production cost from €151,788.44/week to €48.47/week. It means, the Taguchi Loss Function method can eliminate production costs by €151,739.97/week or Rp.2,566,814,683.68-/week.