“It’s a black art”: “design of experiments” switches on the light

Advancing technology applied to engineering production processes can result in improved output quality. However, customer requirements for improved product quality are progressing at a comparable or faster rate, which can result in increased rework and scrap levels when operating at the limits of the technology available. Competitive advantage is only possible through a better understanding of the process itself. Many processes are perceived by those who design and operate them as bordering on a “black art”, due to a limited knowledge of the complex interactions inherent in the process. With the emphasis on continuous improvement, organisations need to address the intricacies and relationships within these processes in order to overcome the quality problems they are experiencing. A case study of a low‐pressure casting process demonstrates the effectiveness and benefits of using Taguchi techniques and “Design of experiments” to provide enlightenment on the complex interrelationships inherent in this “black art” process.