Process capability – a surrogate measure of process robustness: a case study

Purpose – The purpose of this paper is to obtain a better understanding on robust performance of a hardening and tempering process producing component worm shaft used in the steam power plant. This research is capable to explaining the variation of process capability in terms of robustness. Design/methodology/approach – This paper proposed a methodology (a combination of simulation, regression modelling and robust design technique) to study robustness of a hardening and tempering process producing component worm shaft used in the steam power plant and process capability acts as a surrogate measure of robustness. In each experimental run, the values of responses and the corresponding multivariate process capability indices across the outer array are determined. The variation of process performance (process capability values) due to random noise variation is studied using a general purpose process control chart (R-chart). Findings – The results provide useful information in term of insensitiveness of the process against the noise (raw material and process noise) variation where the process capability acts as a surrogate measure of process robustness and explains the variation of process capability in term of robustness. Practical implications – This paper adds to the body of knowledge on robustness of a manufacturing process. This paper may be of particular interest to practicing engineers as it suggests what factors should be more emphasis to achieve robust (consistent) performance from the process. Originality/value – The originality of this paper lies within the context in which this study is to address key relationships between process robustness and process capability in a manufacturing industry.