The new ultraminiature KMS tact switch was developed by ITT Cannon Switch Products in Dole, France, specifically for the cellular phone market. This switch must perform at least 300,000 operations with two newtons nominal force and a good tactile feel.

A robust design effort was initiated using Dr. Taguchi's dynamic parameter design approach. An L18 orthogonal array was used to evaluate the control factors with respect to the signal factor (dome travel), the response (actuating force) and the noise factors (process & material variations and number of operational cycles). The numerical experiments were carried out by using computer simulations only.

The Signal-to-Noise ratio increased 48.7 db as a result of this optimization. The analysis and selection of the best system parameters confirmed the process estimates and resulted in a design with dramatically improved mechanical and reliability performance. KMS production sales are estimated at $ 30,000 K in 2001.

A computer simulation was used to optimize an electrical connector product design and associated plastic injection molding process. Dr. Genichi Taguchi's parameter optimization method, in conjunction with finite element computer simulation, was used to eliminate the need to fabricate expensive tooling and molded parts. [Faster, more robust product/Process designs.]

The electrical connector product functions by creating a signal path between a computer chip embedded in a credit card, called a "smart card" , used extensively in Europe, and the machine in which it is mounted, enabling immediate communication with a remotely located computer. In order to function correctly, the electrical connector must be flat and free of dimensional distortion in order to allow reliable insertion of the credit card and proper electrical connection to the embedded computer chip.

Three approaches were studied and compared to determine which provides the best set of product/process design parameter values. Smaller-the-better Z-axis deflection, dynamic Z-axis position, and dynamic "mold dimension" vs. "part dimension" approaches were compared with respect to the resulting part flatness (Z-axis deflection).

Here we give a discussion, including the development of a new quality characteristic, the waviness index, of the robust design of an injection-molded part currently in use on the Chevrolet Avalanche. We became involved in this project as the Avalanche approached production launch. The part considered, known as the "outer sail panel", threatened to delay the projected launch date unless significant improvement was made in surface quality of the part. Robust design methodology was applied to drastically reduce the surface waviness of the part by optimizing the signal-to-noise ratio of the waviness index. Significant improvement was achieved in a very short time, and with the improvement team working under intense time constraint.