Title: Robust design of hydrodynamic bearings: adopting Taguchi methods towards zero defects of a hermetic compressor

Authors: Suresh Akella; Leela Prasad; N. Venkateswarlu

Addresses: Department of Mechanical Engineering, Vignan Institute of Technology & Science, Vignan Hills, Deshmukhi, Nalgonda District, 508284, India. ' Department of Mechanical Engineering, Vignan Institute of Technology & Science, Vignan Hills, Deshmukhi, Nalgonda District, 508284, India. ' Department of Mechanical Engineering, Vignan Institute of Technology & Science, Vignan Hills, Deshmukhi, Nalgonda District, 508284, India

Abstract: Indian manufacturing companies have passed through the conventional manufacturing with quality control systems, 100% inspection, to a quality assuring TQM companies with robust designs to obtain PPM levels of customer returns. This study is about the hydrodynamic lubrication system in a hermetically sealed compressor to reduce the Taguchi loss function of bearing wear. Taguchi loss function is modified to include warranty. Loss/warranty period is a new parameter introduced. This parameter is lower the better, a lower value indicates less loss to society, more warranty period to customer. A product with less loss/warranty will lead to increased business to manufacturer. This parameter is used for the benefit of society, customer has more warranty period and increased business for the manufacturer. Study of warranty returned compressors was done to obtain the distribution of defects. System design, parameter design and tolerance design approach of Taguchi was adopted to obtain robustness. An improved life of product was obtained. Customers were provided with compressors so that the warranty may be increased from 18 months to five years, with no financial loss also the manufacturer had consistent reliable products.

Keywords: Taguchi methods; hydrodynamic bearings; hermetic compressors; Taguchi loss function; robust design; warranty tolerances; zero defects; India; hydrodynamic lubrication; bearing wear; warranty periods; system design; parameter design; tolerance design.

DOI: 10.1504/IJPTECH.2011.044900

International Journal of Precision Technology, 2011 Vol.2 No.4, pp.313 - 324

Published online: 15 Jan 2012 *

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