A critical look at Taguchi's modelling approach for robust design

The objective of Taguchi's robust design method is to reduce the output variation from the target (the desired output) by making the performance insensitive to noise, such as manufacturing imperfections, environmental variations and deterioration. This objective has been recognized to be very effective in improving product and manufacturing process design. In application, however, Taguchi's analysis approach of modelling the average loss (or signal-to-noise ratios) may lead to non-optimal solutions, efficiency loss and information loss. In addition, since his modelling loss approach requires a special experimental format that contains a cross-product of two separate arrays for control and noise factors, this leads to less flexible and unnecessarily expensive experiments. The response model approach, an alternative approach proposed by Welch et al. , Box and Jones, Lucas and Shoemaker et al. , does not have these problems. However, this alternative approach also has its own problems. This paper reviews and discusses the potential problems of Taguchi's modelling approach. We illustrate these problems with examples and numerical studies. We also compare the advantages and disadvantages of Taguchi's approach and the alternative approach.