Search results for: real time control

Authors: W. Chattinnawat

Abstract:

Consider a mass production of HDD arms where hundreds of CNC machines are used to manufacturer the HDD arms. According to an overwhelming number of machines and models of arm, construction of separate control chart for monitoring each HDD arm model by each machine is not feasible. This research proposed a strategy to optimize the SPC management on shop floor. The procedure started from identifying the clusters of the machine with similar manufacturing performance using clustering technique. The three way control chart ( I - MR - R ) is then applied to each clustered group of machine. This proposed research has advantageous to the manufacturer in terms of not only better performance of the SPC but also the quality management paradigm.

Keywords: Three way control chart. I - MR - R , between/within variation, HDD arm.

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Authors: Seyed Habib A. Rahmati, Mohsen Sadegh Amalnick

Abstract:

Different terms of the Statistical Process Control (SPC) has sketch in the fuzzy environment. However, Measurement System Analysis (MSA), as a main branch of the SPC, is rarely investigated in fuzzy area. This procedure assesses the suitability of the data to be used in later stages or decisions of the SPC. Therefore, this research focuses on some important measures of MSA and through a new method introduces the measures in fuzzy environment. In this method, which works based on Buckley approach, imprecision and vagueness nature of the real world measurement are considered simultaneously. To do so, fuzzy version of the gauge capability (Cg and Cgk) are introduced. The method is also explained through example clearly.

Keywords: SPC, MSA, gauge capability, Cg, Cgk.

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Authors: Ons Sassi, Wahiba Ramdane Cherif-Khettaf, Ammar Oulamara

Abstract:

In this paper, we consider the vehicle routing problem with mixed fleet of conventional and heterogenous electric vehicles and time dependent charging costs, denoted VRP-HFCC, in which a set of geographically scattered customers have to be served by a mixed fleet of vehicles composed of a heterogenous fleet of Electric Vehicles (EVs), having different battery capacities and operating costs, and Conventional Vehicles (CVs). We include the possibility of charging EVs in the available charging stations during the routes in order to serve all customers. Each charging station offers charging service with a known technology of chargers and time dependent charging costs. Charging stations are also subject to operating time windows constraints. EVs are not necessarily compatible with all available charging technologies and a partial charging is allowed. Intermittent charging at the depot is also allowed provided that constraints related to the electricity grid are satisfied. The objective is to minimize the number of employed vehicles and then minimize the total travel and charging costs. In this study, we present a Mixed Integer Programming Model and develop a Charging Routing Heuristic and a Local Search Heuristic based on the Inject-Eject routine with different insertion methods. All heuristics are tested on real data instances.

Keywords: charging problem, electric vehicle, heuristics, local search, optimization, routing problem.

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Authors: Shyam S.N. Perera

Abstract:

The optimal control problem for the viscoelastic melt spinning process has not been reported yet in the literature. In this study, an optimal control problem for a mathematical model of a viscoelastic melt spinning process is considered. Maxwell-Oldroyd model is used to describe the rheology of the polymeric material, the fiber is made of. The extrusion velocity of the polymer at the spinneret as well as the velocity and the temperature of the quench air and the fiber length serve as control variables. A constrained optimization problem is derived and the first–order optimality system is set up to obtain the adjoint equations. Numerical solutions are carried out using a steepest descent algorithm. A computer program in MATLAB is developed for simulations.

Keywords: Fiber spinning, Maxwell-Oldroyd, Optimal control, First-order optimality system, Adjoint system

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Authors: Ying Huang, Zhiliang Wang, An Ping

Abstract:

With advances in computer vision, non-contact gaze tracking systems are heading towards being much easier to operate and more comfortable for use, the technique proposed in this paper is specially designed for achieving these goals. For the convenience in operation, the proposal aims at the system with simple configuration which is composed of a fixed wide angle camera and dual infrared illuminators. Then in order to enhance the usability of the system based on single camera, a self-adjusting method which is called Real-time gaze Tracking Algorithm with head movement Compensation (RTAC) is developed for estimating the gaze direction under natural head movement and simplifying the calibration procedure at the same time. According to the actual evaluations, the average accuracy of about 1° is achieved over a field of 20×15×15 cm3.

Keywords: computer vision, gaze tracking, human-computer interaction.

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Authors: E. Dahlen

Abstract:

Inflation can be calculated from either the prices of consumer products or from salaries. This paper presents a logical exercise that shows it is easier to calculate inflation from salaries than from consumer products. While the prices of consumer products may change due to technological advancement, such as automation, which must be corrected for, salaries do not. If technological advancements are not accounted for within calculations based on consumer product prices, inflation can be confused with real wage changes, since both inflation and real wage changes affect the prices of consumer products. The method employed in this paper is a logical exercise. Logical arguments are presented that suggest the existence of many different feasible ways by which inflation can be determined. Then a short mathematical exercise will be presented which shows that one of these methods –using salaries – contains the fewest number of unknown parameters, and hence, is the preferred method, since the risk of mistakes is lower. From the results, it can be concluded that salaries, rather than consumer products, should be used to calculate inflation.

Keywords: Inflation, logic, math, real wages.

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Authors: Pierre Kancir, Jean-Philippe Diguet, Marc Sevaux

Abstract:

One of the main difficulties in developing multi-robot systems (MRS) is related to the simulation and testing tools available. Indeed, if the differences between simulations and real robots are too significant, the transition from the simulation to the robot won’t be possible without another long development phase and won’t permit to validate the simulation. Moreover, the testing of different algorithmic solutions or modifications of robots requires a strong knowledge of current tools and a significant development time. Therefore, the availability of tools for MRS, mainly with flying drones, is crucial to enable the industrial emergence of these systems. This research aims to present the most commonly used tools for MRS simulations and their main shortcomings and presents complementary tools to improve the productivity of designers in the development of multi-vehicle solutions focused on a fast learning curve and rapid transition from simulations to real usage. The proposed contributions are based on existing open source tools as Gazebo simulator combined with ROS (Robot Operating System) and the open-source multi-platform autopilot ArduPilot to bring them to a broad audience.

Keywords: ROS, ArduPilot, MRS, simulation, drones, Gazebo.

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Authors: Anjana Goen, D. C. Tiwari

Abstract:

Myoelectric control system is the fundamental component of modern prostheses, which uses the myoelectric signals from an individual’s muscles to control the prosthesis movements. The surface electromyogram signal (sEMG) being noninvasive has been used as an input to prostheses controllers for many years. Recent technological advances has led to the development of implantable myoelectric sensors which enable the internal myoelectric signal (MES) to be used as input to these prostheses controllers. The intramuscular measurement can provide focal recordings from deep muscles of the forearm and independent signals relatively free of crosstalk thus allowing for more independent control sites. However, little work has been done to compare the two inputs. In this paper we have compared the classification accuracy of six pattern recognition based myoelectric controllers which use surface myoelectric signals recorded using untargeted (symmetric) surface electrode arrays to the same controllers with multichannel intramuscular myolectric signals from targeted intramuscular electrodes as inputs. There was no significant enhancement in the classification accuracy as a result of using the intramuscular EMG measurement technique when compared to the results acquired using the surface EMG measurement technique. Impressive classification accuracy (99%) could be achieved by optimally selecting only five channels of surface EMG.

Keywords: Discriminant Locality Preserving Projections (DLPP), myoelectric signal (MES), Sparse Principal Component Analysis (SPCA), Time Frequency Representations (TFRs).

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Authors: J. Liu, Z. P. Yu, L. Xiong, Y. Feng, J. He

Abstract:

According to the independence, accuracy and controllability of the driving/braking torque of the distributed drive electric vehicle, a control strategy of differential drive assisted steering was designed. Firstly, the assisted curve under different speed and steering wheel torque was developed and the differential torques were distributed to the right and left front wheels. Then the steering return ability assisted control algorithm was designed. At last, the joint simulation was conducted by CarSim/Simulink. The result indicated: the differential drive assisted steering algorithm could provide enough steering drive-assisted under low speed and improve the steering portability. Along with the increase of the speed, the provided steering drive-assisted decreased. With the control algorithm, the steering stiffness of the steering system increased along with the increase of the speed, which ensures the driver’s road feeling. The control algorithm of differential drive assisted steering could avoid the understeer under low speed effectively.

Keywords: Differential assisted steering, control strategy, distributed drive electric vehicle.

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Authors: Tianchai Suksri, U-thai Sritheeravirojana, Arjin Numsomran, Viriya Kongrattana, Thongchai Werataweemart

Abstract:

A control system design with Characteristic Ratio Assignment (CRA) is proven that effective for SISO control design. But the control system design for MIMO via CRA is not concrete procedure. In this paper presents the control system design method for quadruple-tank process via CRA. By using the decentralized method for both minimum phase and non-minimum phase are made. The results from PI and PID controller design via CRA can be illustrated the validity of our approach by MATLAB.

Keywords: CRA, Quadruple-Tank.

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Authors: Maan M. Shaker

Abstract:

The electroencephalograph (EEG) signal is one of the most widely signal used in the bioinformatics field due to its rich information about human tasks. In this work EEG waves classification is achieved using the Discrete Wavelet Transform DWT with Fast Fourier Transform (FFT) by adopting the normalized EEG data. The DWT is used as a classifier of the EEG wave's frequencies, while FFT is implemented to visualize the EEG waves in multi-resolution of DWT. Several real EEG data sets (real EEG data for both normal and abnormal persons) have been tested and the results improve the validity of the proposed technique.

Keywords: Bioinformatics, DWT, EEG waves, FFT.

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Authors: Truong Nguyen Luan Vu, Le Hieu Giang, Le Linh

Abstract:

The fractional–order proportional integral (FOPI) controller tuning rules based on the fractional calculus for the cascade control system are systematically proposed in this paper. Accordingly, the ideal controller is obtained by using internal model control (IMC) approach for both the inner and outer loops, which gives the desired closed-loop responses. On the basis of the fractional calculus, the analytical tuning rules of FOPI controller for the inner loop can be established in the frequency domain. Besides, the outer loop is tuned by using any integer PI/PID controller tuning rules in the literature. The simulation study is considered for the stable process model and the results demonstrate the simplicity, flexibility, and effectiveness of the proposed method for the cascade control system in compared with the other methods.

Keywords: Fractional calculus, fractional–order proportional integral controller, cascade control system, internal model control approach.

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Authors: M. P. Nanda Kumar, K. Dheeraj

Abstract:

The design of a feedback controller, so as to minimize a given performance criterion, for a general non-linear dynamical system is difficult; if not impossible. But for a large class of non-linear dynamical systems, the open loop control that minimizes a performance criterion can be obtained using calculus of variations and Pontryagin’s minimum principle. In this paper, the open loop optimal trajectories, that minimizes a given performance measure, is used to train the neural network whose inputs are state variables of non-linear dynamical systems and the open loop optimal control as the desired output. This trained neural network is used as the feedback controller. In other words, attempts are made here to solve the “inverse optimal control problem” by using the state and control trajectories that are optimal in an open loop sense.

Keywords: Inverse Optimal Control, Radial basis function neural network, Controller Design.

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Authors: S. Gherbi, F. Bouchareb

Abstract:

This paper deals with the novel intelligent bio-inspired control strategies, it presents a novel approach based on an optimal fuzzy immune PID parameters tuning, it is a combination of a PID controller, inspired by the human immune mechanism with fuzzy logic. Such controller offers more possibilities to deal with the delayed systems control difficulties due to the delay term. Indeed, we use an optimization approach to tune the four parameters of the controller in addition to the fuzzy function; the obtained controller is implemented in a modified Smith predictor structure, which is well known that it is the most efficient to the control of delayed systems. The application of the presented approach to control a three tank delay system shows good performances and proves the efficiency of the method.

Keywords: Delayed systems, Fuzzy Immune PID, Optimization, Smith predictor.

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Authors: N. Tadrisi Parsa, A. R. Vali, R. Ghasemi

Abstract:

Diabetes is a growing health problem in worldwide. Especially, the patients with Type 1 diabetes need strict glycemic control because they have deficiency of insulin production. This paper attempts to control blood glucose based on body mathematical body model. The Bergman minimal mathematical model is used to develop the nonlinear controller. A novel back-stepping based sliding mode control (B-SMC) strategy is proposed as a solution that guarantees practical tracking of a desired glucose concentration. In order to show the performance of the proposed design, it is compared with conventional linear and fuzzy controllers which have been done in previous researches. The numerical simulation result shows the advantages of sliding mode back stepping controller design to linear and fuzzy controllers.

Keywords: Back stepping, Bergman Model, Nonlinear control, Sliding mode control.

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Authors: Han-wool Lee, Chin-suk Hong, Weui-bong Jung

Abstract:

In this study, noise characteristics of structure were analyzed in an effort to reduce noise passing through an opening of an enclosure surrounding the structure that generates noise. Enclosures are essential measure to protect noise propagation from operating machinery. Access openings of the enclosures are important path of noise leakage. First, noise characteristics of structure were analyzed and feed-forward noise control was performed using simulation in order to reduce noise passing through the opening of enclosure, which surrounds a structure generating noise. We then implemented a feed-forward controller to actively control the acoustic power through the opening. Finally, we conducted optimization of placement of the reference sensors for several cases of the number of sensors. Good control performances were achieved using the minimum number of microphones arranged an optimal placement.

Keywords: Active Noise Control, Feed-forward Control, Noise Attenuation, Position Optimization.

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Authors: Seongchan Kang, Hongsik Yun, Hyukgil Kim, Minwoo Park

Abstract:

For this study, this researcher conducted a precision network adjustment with QOCA, the precision network adjustment software developed by Jet Propulsion Laboratory, to perform an integrated network adjustment on the Unified Control Points managed by the National Geographic Information Institute. Towards this end, 275 Unified Control Points observed in 2008 were selected before a network adjustment is performed on those 275 Unified Control Points. The RMSE on the discrepancies of coordinates as compared to the results of GLOBK was ±6.07mm along the N axis, ±2.68mm along the E axis and ±6.49mm along the U axis.

Keywords: Network adjustment, QOCA, unified control point.

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Authors: Emad Alenany, M. Adel El-Baz

Abstract:

In this paper, the flow of different classes of patients into a hospital is modelled and analyzed by using the queueing network analyzer (QNA) algorithm and discrete event simulation. Input data for QNA are the rate and variability parameters of the arrival and service times in addition to the number of servers in each facility. Patient flows mostly match real flow for a hospital in Egypt. Based on the analysis of the waiting times, two approaches are suggested for improving performance: Separating patients into service groups, and adopting different service policies for sequencing patients through hospital units. The separation of a specific group of patients, with higher performance target, to be served separately from the rest of patients requiring lower performance target, requires the same capacity while improves performance for the selected group of patients with higher target. Besides, it is shown that adopting the shortest processing time and shortest remaining processing time service policies among other tested policies would results in, respectively, 11.47% and 13.75% reduction in average waiting time relative to first come first served policy.

Keywords: Queueing network, discrete-event simulation, health applications, SPT.

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Authors: Do-Woo Kim, Geon Woo Kim, Jun-Ho Lee, Jong-Wook Han

Abstract:

The home in these days has not one computer connected to the Internet but rather a network of many devices within the home, and that network might be connected to the Internet. In such an environment, the potential for attacks is greatly increased. The general security technology can not apply because of the use of various wired and wireless network, middleware and protocol in digital home environment and a restricted system resource of home information appliances. To offer secure home services home network environments have need of access control for various home devices and information when users want to access. Therefore home network access control for user authorization is a very important issue. In this paper we propose access control model using RBAC in home network environments to provide home users with secure home services.

Keywords: Home network, access control, RBAC, security.

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Authors: Lokendra K. Balyan

Abstract:

In this paper, we present an algorithm for computing a Schur factorization of a real nonsymmetric matrix with ordered diagonal blocks such that upper left blocks contains the largest magnitude eigenvalues. Especially in case of multiple eigenvalues, when matrix is non diagonalizable, we construct an invariant subspaces with few additional tricks which are heuristic and numerical results shows the stability and accuracy of the algorithm.

Keywords: Schur Factorization, Eigenvalues of nonsymmetric matrix, Orthoganal matrix.

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Authors: Hamid Rafiei, Reza Janamiri, Mohammad Hossein Sedaghat, Amir Hatampour

Abstract:

In this work, the results of mixing study by a jet mixer in a tank have been investigated in the laboratory scale. The tank dimensions are H/D=1 and the jet entrance have been considered in the center of upper surface of tank. RNG-k-ε model is used as the turbulent model for the prediction of the pattern of turbulent flow inside the tank. For this purpose, a tank with volume of 110 liter is simulated and it has been divided into 410,000 tetrahedral control cells for performing the calculations. The grids at the vicinity of the nozzle and suction pare are finer to get more accurate results. The experimental results showed that in a vertical jet, the lowest mixing time takes place at 35 degree. In addition, mixing time decreased by increasing the Reynolds number. Furthermore, the CFD simulation predicted the items as well a flow patterns precisely that validates the experiments.

Keywords: Jet mixer, CFD, Turbulent model, Nozzle angle, Mixing time, Reynolds Number.

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Authors: P. Latha, L. Ganesan, N. Ramaraj, P. V. Hari Venkatesh

Abstract:

Motion detection is a basic operation in the selection of significant segments of the video signals. For an effective Human Computer Intelligent Interaction, the computer needs to recognize the motion and track the moving object. Here an efficient neural network system is proposed for motion detection from the static background. This method mainly consists of four parts like Frame Separation, Rough Motion Detection, Network Formation and Training, Object Tracking. This paper can be used to verify real time detections in such a way that it can be used in defense applications, bio-medical applications and robotics. This can also be used for obtaining detection information related to the size, location and direction of motion of moving objects for assessment purposes. The time taken for video tracking by this Neural Network is only few seconds.

Keywords: Frame separation, Correlation Network, Neural network training, Radial Basis Function, object tracking, Motion Detection.

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Authors: Thella Babu Rao, A. Gopala Krishna

Abstract:

This investigation presents the formulation of kerf (width of slit) and optimal control parameter settings of wire electrochemical discharge machining which results minimum possible kerf while machining Al7075/SiCp MMCs. WEDM is proved its efficiency and effectiveness to cut the hard ceramic reinforced MMCs within the permissible budget. Among the distinct performance measures of WEDM process, kerf is an important performance characteristic which determines the dimensional accuracy of the machined component while producing high precision components. The lack of available of the machinability information such advanced MMCs result the more experimentation in the manufacturing industries. Therefore, extensive experimental investigations are essential to provide the database of effect of various control parameters on the kerf while machining such advanced MMCs in WEDM. Literature reviled the significance some of the electrical parameters which are prominent on kerf for machining distinct conventional materials. However, the significance of reinforced particulate size and volume fraction on kerf is highlighted in this work while machining MMCs along with the machining parameters of pulse-on time, pulse-off time and wire tension. Usually, the dimensional tolerances of machined components are decided at the design stage and a machinist pay attention to produce the required dimensional tolerances by setting appropriate machining control variables. However, it is highly difficult to determine the optimal machining settings for such advanced materials on the shop floor. Therefore, in the view of precision of cut, kerf (cutting width) is considered as the measure of performance for the model. It was found from the literature that, the machining conditions of higher fractions of large size SiCp resulting less kerf where as high values of pulse-on time result in a high kerf. A response surface model is used to predict the relative significance of various control variables on kerf. Consequently, a powerful artificial intelligence called genetic algorithms (GA) is used to determine the best combination of the control variable settings. In the next step the conformation test was conducted for the optimal parameter settings and found good agreement between the GA kerf and measured kerf. Hence, it is clearly reveal that the effectiveness and accuracy of the developed model and program to analyze the kerf and to determine its optimal process parameters. The results obtained in this work states that, the resulted optimized parameters are capable of machining the Al7075/SiCp MMCs more efficiently and with better dimensional accuracy.

Keywords: Al7075SiCP MMC, kerf, WEDM, optimization.

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Authors: A. Budiyono

Abstract:

The control design for unmanned underwater vehicles (UUVs) is challenging due to the uncertainties in the complex dynamic modeling of the vehicle as well as its unstructured operational environment. To cope with these difficulties, a practical robust control is therefore desirable. The paper deals with the application of coefficient diagram method (CDM) for a robust control design of an autonomous underwater vehicle. The CDM is an algebraic approach in which the characteristic polynomial and the controller are synthesized simultaneously. Particularly, a coefficient diagram (comparable to Bode diagram) is used effectively to convey pertinent design information and as a measure of trade-off between stability, response speed and robustness. In the polynomial ring, Kharitonov polynomials are employed to analyze the robustness of the controller due to parametric uncertainties.

Keywords: coefficient diagram method, robust control, Kharitonov polynomials, unmanned underwater vehicles.

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Authors: K. Diwakar, N. Vasudevan, C. Senthilpari

Abstract:

This paper presents MOSFET based analog to digital converter which is simple in design, has high resolution, and conversion rate better than dual slope ADC. It has no DAC which will limit the performance, no error in conversion, can operate for wide range of inputs and never become unstable. One of the industrial applications, where the proposed high resolution MOSFET ADC can be used is, for the positioning of control valves in a multi channel data acquisition and control system (DACS), using stepper motors as actuators of control valves. It is observed that in a DACS having ten control valves, 0.02% of positional accuracy of control valves can be achieved with the data update period of 250ms and with stepper motors of maximum pulse rate 20 Kpulses per sec. and minimum pulse width of 2.5 μsec. The reported accuracy so far by other authors is 0.2%, with update period of 255 ms and with 8 bit DAC. The accuracy in the proposed configuration is limited by the available precision stepper motor and not by the MOSFET based ADC.

Keywords: MOSFET based ADC, Actuators, Positional accuracy, Stepper Motors.

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Authors: Teerapun Saeheaw, Nivit Charoenchai, Wichai Chattinnawat

Abstract:

Simulation model is an easy way to build up models to represent real life scenarios, to identify bottlenecks and to enhance system performance. Using a valid simulation model may give several advantages in creating better manufacturing design in order to improve the system performances. This paper presents result of implementing a simulation model to design hard disk drive manufacturing process by applying line balancing to improve both productivity and quality of hard disk drive process. The line balance efficiency showed 86% decrease in work in process, output was increased by an average of 80%, average time in the system was decreased 86% and waiting time was decreased 90%.

Keywords: line balancing, arena, hard disk drive process, simulation, work in process (WIP)

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Authors: Yoshifumi Ishizaki, Naoki Kanatani, Masaki Ito, Toshihiko Sasama, Takao Kawamura, Kazunori Sugahara

Abstract:

This paper demonstrates the bus location system for the route bus through the experiment in the real environment. A bus location system is a system that provides information such as the bus delay and positions. This system uses actual services and positions data of buses, and those information should match data on the database. The system has two possible problems. One, the system could cost high in preparing devices to get bus positions. Two, it could be difficult to match services data of buses. To avoid these problems, we have developed this system at low cost and short time by using the smart phone with GPS and the bus route system. This system realizes the path planning considering bus delay and displaying position of buses on the map. The bus location system was demonstrated on route buses with smart phones for two months.

Keywords: Route Bus, Path Planning System, GPS, Smart Phone.

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Authors: Shahrol Mohamaddan, Keith Case, Ana Sakura Zainal Abidin

Abstract:

Human movement in the real world provides important information for developing human behaviour models and simulations. However, it is difficult to assess ‘real’ human behaviour since there is no established method available. As part of the AUNTSUE (Accessibility and User Needs in Transport – Sustainable Urban Environments) project, this research aimed to propose a method to assess human movement and behaviour in crowded areas. The method is based on the three major steps of video recording, conceptual behavior modelling and video analysis. The focus is on individual human movement and behaviour in normal situations (panic situations are not considered) and the interactions between individuals in localized areas. Emphasis is placed on gaining knowledge of characteristics of human movement and behaviour in the real world that can be modelled in the virtual environment.

Keywords: Video observation, Human movement, Behaviour, Crowds, Ergonomics, AUNT-SUE

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Authors: Jing Zhou, Steven Su, Aihuang Guo

Abstract:

COSMED K4b2 is a portable electrical device designed to test pulmonary functions. It is ideal for many applications that need the measurement of the cardio-respiratory response either in the field or in the lab is capable with the capability to delivery real time data to a sink node or a PC base station with storing data in the memory at the same time. But the actual sensor outputs and data received may contain some errors, such as impulsive noise which can be related to sensors, low batteries, environment or disturbance in data acquisition process. These abnormal outputs might cause misinterpretations of exercise or living activities to persons being monitored. In our paper we propose an effective and feasible method to detect and identify errors in applications by principal component analysis (PCA) and a back propagation (BP) neural network.

Keywords: BP Neural Network, Exercising Testing, Fault Detection and Identification, Principal Component Analysis.

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Authors: Christopher C. Ihueze, Charles C. Okpala, Christian E. Okafor, Peter O. Ogbobe

Abstract:

This paper focuses on robust design and optimization of industrial production wastes. Past literatures were reviewed to case study Clamason Industries Limited (CIL) - a leading ladder-tops manufacturer. A painstaking study of the firm-s practices at the shop floor revealed that Over-production, Waiting time, Excess inventory, and Defects are the major wastes that are impeding their progress and profitability. Design expert8 software was used to apply Taguchi robust design and response surface methodology in order to model, analyse and optimise the wastes cost in CIL. Waiting time and overproduction rank first and second in contributing to the costs of wastes in CIL. For minimal wastes cost the control factors of overproduction, waiting-time, defects and excess-inventory must be set at 0.30, 390.70, 4 and 55.70 respectively for CIL. The optimal value of cost of wastes for the months studied was 22.3679. Finally, a recommendation was made that for the company to enhance their profitability and customer satisfaction, they must adopt the Shingeo Shingo-s Single Minute Exchange of Dies (SMED), which will immediately tackle the waste of waiting by drastically reducing their setup time.

Keywords: Excess-inventory, setup time, single minute exchange of dies, optimal value, over-production, robust design.

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