An Innovative Manufacturing Process

Journal of the Chinese Institute of Industrial Engineers
Vol. 29, No. 7, October 2012, 454465
An innovative manufacturing process for bamboo injection molding by

using TRIZ and Taguchi method
Mu-Tsai Chang* and Chi-Hao Yeh
Department of Industrial Engineering and Management, National Taipei University of
Technology, No. 1, Sec. 3, Chung-Hsiao East Road, Taipei, Taiwan, ROC
(Received February 2012; revised July 2012; accepted August 2012)
The appearance of 3C (computer, communication, consumer electronic) electronic products has been
considered as a critical attribute to attract consumers in the past decade. Moreover, 3C electronic
enterprises with own brands are trying hard to meet the requirements such as user-friendly interface
and eco-environmental materials for increasing the revenue and market share. Bamboo had been
known as a flexible and green raw-material worldwide for many years. However, there are no bamboomade applications in any 3C electronic products due to its manufacturing process to achieve
satisfactory specifications. The innovative manufacturing process of bamboo injection molding on the
appearance of a 3C product suffered from a crucial quality issue, that is, bamboo deformation due to
the difference between shrinkage of plastic and its inherent material characteristics. The concept is
similar to IMR (in-mold decoration by roller) process. The objective of this article is to propose an
innovative and robust bamboo injection molding process by using skills such as measurement system
analysis, the Taguchi method, process capability index, and TRIZ. In this study, the detailed
experimental process and satisfactory result are demonstrated and given. The exploited approach
concerning bamboo is a valuable outcome and reference for further advanced implementations in
electrical industry and others.
Keywords: bamboo injection molding; measurement system analysis; Taguchi method; TRIZ; process
capability index
1. Introduction
Consumers are attracted by the functionalities,
appearance, and price of a 3C (computer, communication, consumer electronic) electronic product.
However, existing manufacturing techniques such
as electroplating and spray painting for an electronic products appearance produce significant
and negative impacts to environment. 3C companies with own brand need to provide more
eco-environment protection while using new
finish-machining methods [7]. Bamboo has many
advantages such as easy to recycle, easy to decompose, and good performance in physical attributes.
It is a suitable material to produce home-living
products. AsusTek, one of brand companies, has
been dedicated in developing innovative
manufacturing process and designed laptops
appearance by using bamboo as main material.
This is the very first bamboo skin onto laptop and
is famous worldwide (Figure 1).
In recent years, in-mold injection has been a
popular manufacturing process in laptop appearance. AsusTek began to explore in-mold injection
molding by using bamboo and give curved and
*Corresponding author. Email: Arthur_chang@asus.com

ISSN 10170669 print/ISSN 21517606 online
2012 Chinese Institute of Industrial Engineers
http://dx.doi.org/10.1080/10170669.2012.727477
http://www.tandfonline.com
double-sided arcs appearance. However, quality

issues suffer from breaking, blisters, wrinkles, and
deformation on bamboo skin (Figure 2). The most
critical issue is the deformation due to different
shrinkage ratios for plastic and bamboo. Since inmold injection molding by using bamboo is the first
attempt all over the world, there is no existing
empirical rule or data to solve the difficult problem.
In this study, an innovative and robust manufacturing approach is exploited to solve the bamboo
deformation occurring in in-mold injection
molding.
The approach is executed by traditional qualityrelated skills such as Taguchis method, MSA by
gauge repeatability and reproducibility (GRR),
process capability index (PCI) by Cpk, t-test by
one-sample t-test, and independent samples t-test.
In addition, TRIZ known as an innovative thinking
methodology is utilized to solve problems never
been met. Although the traditional quality-assurance techniques utilized are not newly developed,
however, the synergy of traditional skills and TRIZ
provides a profitable quality level in such a difficult
manufacturing process.
Figure 1. Asus U6V Bamboo notebook.
Figure 2. Abnormalities at bamboos appearance by

using in-mold injection molding process: (a) breaking, (b)
blisters, (c) wrinkles, and (d) deformation.
2. An innovative and robust manufacturing

approach
The most critical issue is the deformation due to
different shrinkage ratios between plastic and
bamboo (the desired specification for deformation
is 03 mm, mean 14.3 mm, standard deviation
1.04). This article proposes an innovative and
robust manufacturing approach to solve this
unwanted deformation. The problem-solving process is suggested in four steps and is shown in
Figure 3. The detailed experiment arrangement is
explained in the following sections.
2.1 MSA experiment

The MSA is processed at stage A in Figure 3.
The measure system is composed by measuring
instrument, operator, and operational environment. If the measurement variation is too large,
the measurement data may not be appropriate for
further analysis [1]. MSA methodology includes
evaluation bias, evaluation stability, evaluation
discrimination, GRR analysis, Kappa analysis,
etc. The GRR analysis using continuous data is
executed to measure repeatability (the variability
between the operators and equipment) and reproducibility (the variability among the operators) [6].
455
Four basic GRR are defined in terms of %

contribution, % study variation, % tolerance, and
the number of distinct category. The field is
emphatically in precision of measuring instrument,
which holds tolerance ratio [1]. Therefore, %
tolerance is chosen to carry on MSA in this
study, that is, the formulae are as shown in
Equation (1).
q
2
6x
Measurement
System
P
,
1
% Tol
T
USL LSL
where % Tol is the percentage of tolerance, P the
precision, T the tolerance, USL the upper specification limit, and LSL the lower specification limit.
The operational requirements are at least two
operators and six analyses to carry out two times
measurement [1]. The criteria for determining if the
process is capable are: GRR 5 10% is acceptable
(PASS), 10% GRR 5 30% is a conditional
acceptance, and GRR 30% is not acceptable
(NG) based on practical experience for 3C
electronic products.
As mentioned earlier, the deformation is verified by GRR process. The MSA experiment needs
two laboratory operators and 10 injected bamboo
products. Each operator measures his (her) injected
bamboo products for three cycle times. If the GRR
result is NG, the quality assurance department will
ask component suppliers to provide corrective
action report (CAR) for facilitating the measuring
improvement. The measurement system is evaluated again and repeatedly carried out until GRR
result is acceptable (PASS) or a conditional
acceptance.
2.2 TRIZ experiment

The TRIZ method is applied at stage B shown in
Figure 3. TRIZ was invented and developed by
Russian Genrich Altshuller. Genrich Altshuller had
found a variety of different engineering systems and
technologies sharing common evolution, which
have guided people to avoid many fruitless trails
and errors in 1950s.
TRIZ had been proved to be a well-structured
and innovative way of problem solving in technical
and non-technical areas [9]. Many well-known
improvement methods like the Six Sigma, QFD,
the Taguchi method, and DFM/A have recommended TRIZ as a valuable complement for
innovation, no matter in technology, management,
business strategy, and creativity [8]. Therefore,
TRIZ is a feasible innovative theory in solving
many contradictions in engineering and technology. Many practical TRIZ-based usages in engineering area can be reviewed [11]. TRIZ includes
456
M.-T. Chang and C.-H. Yeh
Figure 3. The flow chart of experimental procedure.
Table 1.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
40 TRIZ innovative principles.
Segmentation
Separation
Local quality
Symmetry change
Merge
Multi-functionality
Nested doll
Weight compensation
Preliminary counteraction
Preliminary action
Beforehand compensation
Equi-potentiality
The other way around
Curvature increase
15
16
17
18
19
20
21
22
23
24
25
26
27
Dynamic parts
Partial or excessive actions
Dimensionality change
Mechanical vibration
Periodic action
Continuity of useful action
Hurrying
Blessing in disguise
Feedback
Intermediary
Self-service
Copying
Cheap disposables
contradiction analysis, idle resources utilization,

increasing the ideality of final result, prediction for
the evolution of both problems and solutions, 39
engineering parameters, 40 TRIZ innovative principles, and contradiction matrix [8]. In addition, 40
TRIZ innovative principles have been confirmed to
be shortcuts to ideal final result even without the
analysis of contradictions and resource. They can
be used as independent tools to obtain innovative
or creative ideas for resolving conflicts.
Forty TRIZ innovative principles were developed by Altshuller in the early 1970s. In most
situations, one principle will give a concept for
initial solution, but several iterations may be
needed to achieve a feasible solution. The 40
TRIZ innovative principles are listed in Table 1.
One can find the detailed description of each
innovative principle easily on website or in a
TRIZ-related book.
A technical contradiction (trade-off) means that
when one feature gets better, another feature will
get worse simultaneously. Altshuller had proposed
39 engineering parameters to include all engineering features (Table 2). He also developed and
28
29
30
31
32
33
34
35
36
37
38
39
40
Mechanical interaction substitution

Pneumatics and hydraulics
Flexible shells and thin films
Porous materials
Optical property changes
Homogeneity
Discarding and recovering
Parameter change
Phase transition
Thermal expansion
Strong oxidants
Inert atmosphere
Composite materials
proposed the corresponding 39 39 contradiction

matrix table to indicate the suggested more effective TRIZ innovative principles for solving each
pair of conflicting engineering parameters. That is,
cues for finding innovative principles for each pair
of trade-offs are summarized in the 39 39 contradiction matrix table.
Mann et al. [5] have adjusted 39 engineering
parameters to 48 ones to meet the requirement of
recent and advanced technology. They created
48 48 contradiction matrix referred by their
experience and Altshullers matrix. However, Yeh
[12] had integrated the original 39 39 contradiction matrix by Altshuller and 48 48 contradiction
matrix by Mann et al. into a new 39 39
contradiction matrix. The new 39 39 contradiction matrix contains more suggested innovative
principles, but still 39 parameters remain. In this
study, new 39 39 contradiction matrix is
implemented to find more cues for solving difficult
problems.
For instance, breaking-resistance of a smart
phone is a critical specification in dropping test for
manufacturers. To strengthen a mobile phone from
457

Table 2.
39 TRIZ engineering parameters.
1
2
Weight of moving objects

Weight of stationary objects
14
15
Length of moving objects
16
4
5
Length of stationary objects

Area of moving objects
17
18
6
7
Area of stationary objects

Volume of moving objects
19
20
8
9
10
11
Volume of stationary objects

Speed
Force
Stress or pressure
12
13
Shape
Stability of objects
composition
Table 3.
Strength
Duration of action by
moving object
Duration of action by
stationary object
Temperature
Illumination intensity
27
28
Reliability
Measurement accuracy
29
Manufacturing precision
30
31
32
33
21
22
23
24
Use of energy by moving object

Use of energy by stationary
object
Power
Loss of energy
Loss of substance
Loss of information
External harm affects the object

Object-generated harmful
factors
Ease of manufacture
Ease of operation
25
26
Loss of time
Quantity of substance/matter
38
39
34
35
36
37
Ease of repair
Adaptability or versatility
Device complexity
Difficulty of detecting
and measuring
Extent of automation
Productivity
A portion of new 39 39 contradiction matrix for improved parameter (14) and worsen parameter (36).
Worsen parameters
Improved parameters
12
Shape
13
Stability of
objects
composition
Strength
14
15
16
Duration of
action by
moving object
Duration of
action by
stationary object
34
35
36
1, 28, 29
3, 31
35, 15, 30
29, 2, 10, 34
2, 5, 22
1, 16
31, 2, 10, 40
26, 17, 22
38
28, 37, 13, 31

15, 24, 7, 39
7, 24, 17, 35, 9
37,32,28,23,39
1, 29, 15, 32
2, 25, 35
24, 1, 10, 16
8,14, 35
17, 13, 1, 2
35, 22
2, 10, 24, 16
35, 15, 17, 13
35,
15,
40,
31,
1, 2, 3, 5, 13
24, 25, 3, 11, 27
3, 10, 17, 19, 7
34, 13, 27, 29
40, 35, 1, 4, 17
15, 3, 24, 32
7, 13, 30, 35
1, 17, 4, 40
2, 5, 15, 13, 18
17, 25, 28
5, 15, 10, 4, 2
28, 29, 25
2, 40, 32, 28
13, 15, 18, 3, 27
10, 37, 4, 32, 19
35, 39, 28, 29
15, 2, 35
10,17, 13
10, 30, 17, 6
24, 31, 1, 13
3, 10, 19
1, 28, 13
13, 5, 4, 17
2, 35, 40
5, 10, 2, 25, 4
17, 14
32, 35, 25, 6,

4, 37, 39, 28
1, 17, 13
24, 6, 31
breaking, designers often add more parts or design

complicated inner structure. However, more parts
and assembling cost are incurred. In this case,
smart phone manufacturers want to enhance
strength but avoid the system getting complicated
simultaneously. Therefore, the improved engineering parameter is selected to be strength (14) and
worsen engineering parameter is decided to be
system complexity (36). The TRIZ innovative
principles 2, 5, 15, 13, 18, 17, 25, and 28 based on
new 39 39 contradiction matrix have the largest possibility to solve this conflict (Table 3), unlike
the original contradiction matrix developed by
Altshuller. The innovative principles 2, 5, 15, 13,
18, 17, 25, and 28 have equal probability to solve
corresponding trade-off conflicts. Notice that other
32 innovative principles could suggest innovative
29,
28,
13,
35,
37
solutions as well, so it is not surprised if the

solutions come from the rest of 32 innovative
principles. Original TRIZ 39 39 contradiction
matrix could be easily found in any TRIZ-related
books or website.
The execution of TRIZ methodology is
arranged into five steps as follows:
(1) Problem description: A problem description
identifies problems, errors, or causes. To
collect all data and documents that might
be helpful to define the problem more
precisely. Generally, three levels method,
5W1H (Who, What, Where, When, Why,
and How), nine windows, diagram of
source of error the problem the
negative effect, and so on are suggested
to execute this task.
458
(2) Contradiction analysis: Defining the

improved
and
worsen
engineering
parameters in problem description step,
respectively.
(3) Contradiction matrix and innovative principles: Using contradiction matrix to select
suggested innovative principles for guiding
solutions.
(4) Exploring alternative solutions based on
suggested innovative principles: Using brain
storming, mind mapping, or six thinking
hats to find alternative and feasible solutions to ease or solve problems.
(5) Evaluation for ideality of proposed solutions: Judging the most ideal and feasible
solution among alternatives with respect to
limited resource. The selected solution will
be further processed by the Taguchi method
for optimal manufacturing parameters.
2.3 Taguchi experiment

The Taguchi experimental design is applied at stage
C shown in Figure 3. Finding key factors such as
female molding temperature, male molding temperature, holding pressure, holding pressure time,
and cooling time in bamboo injection molding are
decided by designers experiences, trial errors, and
feedback from further manual visual inspection.
That will be time-consuming to conduct a fullfactorial analysis. In addition, the Taguchi
experimental design provides a simple, efficient,
and systematic approach to optimize designs for
performance, quality, and cost with a minimum
amount of testing [10]. Therefore, the static orthogonal array configuration of the Taguchi experimental design is used to measure bamboo
deformation and find out the most appropriate
factors. The analysis of main effects plot for means
and SN ratios is able to find out most appropriate
factors.
This stage is divided into three steps as follows:
(1) identifying the key factors causing quality
in stability in bamboo injection molding,
(2) based on the setting values of existing
bamboo injection molding factors, selecting
appropriate Taguchi orthogonal array configuration and
(3) finding out the bamboo injection molding
factors via analysis of the main effects plot
for means and SN ratios. In addition, any
adjustable factor(s) for moving toward to
nominal value should be identified.
Once the optimal parameters are found, PCI
mass production evaluation is executed. If they are
not found, Taguchi experimental design will
Figure 4. The deformation description of front cover of

bamboo injection molding.
continue until the optimal manufacturing parameters factor is found.
2.4 PCI experiment

PCIs are widely used to measure the manufacturability of process and judge whether meeting
established specification limits [4]. There are four
basic PCIs: Cp, Cpk, Cpm, and Cpmk. The Cpk is
used to carry on the PCI analysis in this study [2,3].
The formula is as shown in Equation (2).
Cpk
MINX LSL, USL X

,
3
where X is the mean, the standard deviation,

USL the upper specification limit, and LSL the
lower specification limit. To use Cpk, it requires
pre-defined specific quality management plan
(QMP). The criteria for determining the capability
of process are: CpkActual CpkNominal is considered
as acceptable (PASS), CpkNominal 4CpkActual
CpkNominal 0.9 is a conditional acceptance, and
CpkNominal 0.9 4 CpkActual is considered as unacceptable (NG).
The factors of bamboo injection molding are
verified by Cpk to determine whether they meet the
acceptable production yield for current demands.
The acceptance of CpkActual is pre-defined by
specific QMP. When the CpkActual is NG, components suppliers need to provide the CAR for
effective improvement action. Then, the Taguchi
experimental design implementation will be executed once more. The process will be carried out
repeatedly until the CpkActual is not NG.
3. Experimental results
The front cover of ASUS NB U43 is selected to be
testing sample in this study. The front cover is
made by TN3715B plastics and restricted to 28 mm
thickness. Similar to IMR process, bamboo skin is
decorated onto the plastic front cover. A lot of
deformed occurrences on front covers are found
after injection. To verify the magnitude of deformation, a jig with feeler gauge on the mid-point of
testing samples was used. The desired deformation
is less than 3 mm, however, the resulting
deformation is close to 14.3 mm (Figure 4).

Table 4.
MSA data collection table.

Data
Operational definition and procedure
Measure data
Data type
Measure tools
Deformation
Continue
type
Measure
Fixture
Table 5.
459
Data type
Measure data
Data type
Record sample no
Date time
Operational personnel
Measurer: two persons

Sample: 10 pieces
Repeatability: three times
GRR form
The deformation of raw data for the MSA experiment.
Furthermore, the desired thickness of bamboo skin

on front cover of ASUS NB U43 is 3.5 mm. A 450
ton stand-up forming machine is used in this
experiment.
3.1 MSAGRR result

The deformation of testing samples are measured
and collected. The data collection plan is listed in
Table 4. The GRR measurement for deformation is
12.3% (repeatability 11.9% and reproducibility 3.4%), which gives a PASS result.
In addition, the testing raw data are shown in
Table 5. Therefore, the process can move to
stage B,
3.2 TRIZ implementation

3.2.1 Problem description
The plastic front cover and bamboo skin are
processed by injection molding, the resulting synergy will be released after a period of pressure and
stress. Because of different shrinkage ratios of
plastic front cover and bamboo skin, it generates
serious
deformation
(specification:
3 mm,
average 14.31 mm; standard deviation 1.04;
p 0.753 0.05, it is normally distributed;
Cpk 3.31 5 1.33).
3.2.2 Contradiction analysis

If we need to improve stress and pressure, at the
same time, the liner size for the synergy of plastic
front cover and bamboo skin should remain
stationary as possible. This is a typical trade-off
contradiction. TRIZ are used to find cues and solve
this contradiction. The improved engineering
parameter is stress or pressure (11) and the
worsen parameter is length of stationary objects
(4), The suggested innovative principles to solve
this contradiction are listed in new 39 39 contradiction matrix (Table 6).
3.2.3 Contradiction matrix and suggested innovative principles
The suggested innovative principles can be found in
Table 6: Principle 3 (local Quality), Principle14
(curvature increase), Principle 17 (dimensionality
change), Principle 35 (parameter change), Principle
40 (composite materials), Principle 4 (symmetry
change), Principle 9 (preliminary counteraction),
and Principle 1 (segmentation).
3.2.4 Exploring alternative solutions based on
suggested innovative principles
According to suggested innovative principles in the
previous section, the project team leader invited
460
Table 6.
A portion of new 39 39 contradiction matrix for improved parameter (11) and worsen parameter (4).
Worsen parameters
Improved parameters
09
Speed
10
Force
11
Stress or pressure
12
Shape
13
Stability of objects
composition
Table 7.
1, 13, 2
10, 35, 3
9, 13, 28, 1
35, 40, 18
35, 10, 13, 31
29, 40, 2, 17, 18
15, 3, 10, 31
26, 35, 40
40, 35, 31, 17
39, 1, 24, 4, 26
13, 17, 28, 2

29, 14, 1, 8
17, 35, 9, 3, 14
19, 28, 36, 29
35, 9, 40, 17, 3
14, 4, 13, 10, 36
4, 14, 29, 5
15, 13, 2, 7, 34
17, 1, 35, 13
15, 13, 2, 7, 34
17, 15, 30
2, 14, 1
35, 28, 17, 9
40, 10, 37
3, 14, 17, 35
40, 4, 9, 1
17, 14, 4, 13
5, 7, 31, 10
17, 4, 35, 37
13, 1, 40
17, 14, 4, 1, 29
30, 3, 5, 34
15, 17, 10, 14 19,
3, 29, 39, 40
10, 35, 40, 14
17, 28, 15, 3, 16
4, 17, 5, 2, 14
32, 10, 34
31, 13, 11, 35
17, 4, 3, 2, 12
14, 5, 3, 17
1, 4, 13
1, 3, 17, 40, 37
18, 36, 9, 35
40, 14, 35, 10
37, 17, 3, 15, 36
17, 14, 5, 28
2, 32, 4
35, 31, 4, 3
39, 13, 17
Conceptualized solutions inspired by suggested innovative principles.
Innovative principle
Inspired solution(s)
3
14
17
Local quality
Curvature increase
Dimensionality change
None so far
None so far
Yes
35
Parameter change
Yes
40
Composite materials
Yes
4
9
Symmetry change
Preliminary
counteraction
None so far
Yes
Segmentation
None so far
Conceptualized description
Changing the direction of gel-gate in mold and making it a ribshape to reduce the magnitude of deformation
By increasing holding time and holding pressure, the product
density does not shrink easily
Adding another bamboo skin at the back side of plastic for
supporting purpose while processing injection-molding. In
this manner, the forming force is evenly distributed so the
shrinkage could be minimized
Changing the forming parameters to achieve deformation in

the opposite direction in advance, the resulting synergy of
bamboo skin and plastic will achieve normal flatness due to
this prior action
experts good at injection, physical characteristics of

bamboo skin, molding, and mechanical design to
work together for potential and feasible solutions.
Each suggested innovative principle could not lead
to a conceptual or feasible solution or more. The
resulting solutions guided by suggested innovative
principles and conceptualized by the project team
are demonstrated in Table 7.
3.2.5 Evaluation for ideality for proposed

solutions
The conceptual solutions inspired by TRIZ innovative principles such as 17, 35, 40, and 9 are
proposed and verified in this step. They are
described as follows:
(1) Principle 17 (dimensionality change)
A rib-shape design is applied to plastic
structure to increase supporting force and
reduce bending deformation. Hence, the
gate of injection molding is changed from
two gates to length-extending one

(Figure 5). Thirty-five pieces of bamboo
skin by injection molding were verified using
this proposed solution.
The result shows that the specification of
deformation is 03 mm, the average of the
deformation is 10.14 mm, the standard deviation is 0.83 mm, and p 0.056 0.05. It is
normally distributed and the resulting
Cpk 2.82 5 1.33. However, it does not
meet the pre-defined specification. But the
independent samples t-test result shows that
the improvement of deviation is obvious
(p 0.000 5 0.05).
(2) Principle 35 (parameter change)
After plastic injection molding, gaps
between plastic molecules are produced.
By switching holding pressure and
holding time, plastic molecules can be
tighter,
thereby
reducing
shrinkage
and deformation. The original holding
461
Figure 6. The improved testing sample using TRIZ

innovative principle 40 (right) and the original testing
sample (left).
Figure 5. Rib-shape design is applied to plastic structure:
(a) two gates and (b) the length-extending gate.
pressure is set to 20 and holding time is set

to 8 s. They are switched to 40 and 12 s,
respectively. Thirty-five pieces of bamboo
skin by injection molding are verified using
this proposed solution.
Cpk 0.74 5 1.33. However, it does not
meet the pre-defined specification. But the
(p 0.000 5 0.05). Unfortunately, larger
holding pressure and longer holding time
tend to reduce the production capacity for
injection molding. Therefore, further experiments by the Taguchi method for investigating the most appropriate forming
parameters are necessary.
(3) Principle 40 (composite materials)
The surface of bamboo skin and plastic may
not shrink concurrently in processing injection molding. Therefore, the deformation is
caused by distortion. In this study, another
bamboo skin is added at the back side of
plastic. In this manner, the tension formed
on both sides is evenly distributed. The
shrinkage and deformation could be minimized as much as possible. Thirty-five pieces
of bamboo skin by injection molding are
verified using this proposed solution.
deformation
is
1.14 mm
(maximum 1.6 mm; minimum 0.6 mm), the
standard deviation is 0.265 mm, and
p 0.336 0.05. It is normally distributed
and the resulting Cpk 1.42 4 1.33. It
meets the pre-defined specification. But the
(p 0.000 5 0.05). One of the specimens is
shown in Figure 6.
(4) Principle 9 (prior counteraction)

By pre-heating, the male and female molds
are set to appropriate temperature difference, the plastic will be in arch-shape but in
opposite direction. And more blending
stress is produced and released by increasing
cooling time. The temperature difference
between male and female molds is originally
around 20 C, switching to around 40 C.
The original cooling time is around 10 s,
switching to 20 s. Thirty-five pieces of
bamboo skin by injection molding are verified using this proposed solution.
Cpk 2.6 5 1.33. It does not meet the
pre-defined specification. However, the
independent samples t-test result shows
that the improvement of deviation is obvious (p 0.000 5 0.05). Unfortunately, more
cooling time tends to reduce the production
capacity for injection molding. Therefore,
further experiments by the Taguchi method
for investigating the most appropriate forming parameters are necessary.
In practice, using only one inspired solution by
TRIZ may not fully achieve higher ideality if the
problem is very difficult. Therefore, four solutions
aforementioned are used to reach high ideality or
specification. The solution inspired by principle 40
(composite materials) is able to meet the
specification. Implementing this solution aided
by changing two plastic mold gates to lengthextending one (principle 17: dimensionality
change). Furthermore, further experiments by the
Taguchi method for investigating the most appropriate forming parameters are necessary as well
(Principle 35: parameter change and Principle 9:
prior counteraction).
3.3 Taguchi experimental design result
3.3.1 Identifying the key factor of the bamboo
injection molding
Since further experiments by the Taguchi method
for investigating the most appropriate forming
462
Table 8.
Experimental data of bamboo injection molding.

Factors
Sample data
Basic statistics
Run
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
40
40
40
40
40
40
40
40
40
65
65
65
65
65
65
65
65
65
90
90
90
90
90
90
90
90
90
40
40
40
65
65
65
90
90
90
40
40
40
65
65
65
90
90
90
40
40
40
65
65
65
90
90
90
20
20
20
30
30
30
40
40
40
30
30
30
40
40
40
20
20
20
40
40
40
20
20
20
30
30
30
8
8
8
10
10
10
12
12
12
12
12
12
8
8
8
10
10
10
10
10
10
12
12
12
8
8
8
10
15
20
10
15
20
10
15
20
10
15
20
10
15
20
10
15
20
10
15
20
10
15
20
10
15
20
2.2
1.7
1.7
1.5
1.7
1.9
1.9
1.9
1.8
1.2
0.9
1
1.2
1.1
1.2
1.6
1.4
1.2
0.6
0.5
0.4
0.9
0.8
0.6
0.8
0.9
0.7
2
1.6
1.7
1.6
1.7
2
2.1
1.8
1.7
1.1
0.8
1.2
1.2
1.1
1.2
1.6
1.3
1.3
0.5
0.5
0.4
0.8
0.7
0.7
0.7
0.9
0.7
1.9
1.7
1.6
1.5
1.6
2.1
1.8
1.7
1.8
1.1
0.9
1.1
1
1.2
1.2
1.4
1.2
1.4
0.5
0.5
0.5
1.1
0.7
0.8
0.9
0.8
0.9
2.1
1.6
1.8
1.6
1.7
1.9
1.7
1.8
1.6
1.1
0.9
1.1
1.2
1.2
1.2
1.7
1.4
1.3
0.5
0.5
0.5
1.1
0.7
0.7
0.9
0.9
0.8
2
1.7
1.6
1.6
1.8
1.8
1.8
1.7
1.9
1.1
0.9
1.1
1.1
1.2
1.1
1.6
1.4
1.3
0.5
0.4
0.5
1
0.8
0.7
0.9
1
0.8
1.8
1.8
1.8
1.7
1.7
1.8
1.9
1.8
1.5
1
0.9
1.1
1.2
1.2
1.2
1.5
1.5
1.3
0.5
0.4
0.6
1
0.8
0.7
0.9
0.8
0.8
parameters are necessary, key and controllable

factors for bamboo injection molding are listed
and abbreviated by AE as follows:
. A: female mold temperature (40 C, 65 C,
90 C, three levels);
. B: male mold temperature (40 C, 65 C,
90 C, three levels);
. C: hold pressure (20, 30, 40 pressure, three
levels);
. D: hold time (8, 10, 12 s, three levels);
. E: cold time (10, 15, 20 s, three levels).
3.3.2 Taguchi orthogonal array configuration

In this section, an optimal combination of factors
for bamboo injection molding process is identified
by constrained developing time and manufacturing
unit cost for mass production. Based on the setting
value of existing bamboo injection molding parameters by L27(35) orthogonal configuration (Table 8),
there are six testing samples for each run.
Therefore, there are 162 pieces testing samples,
that is, 6 (injected testing samples) 27 (runs). The
experimental data for the averages of deformation
are listed in Table 8.
2.00
1.68
1.70
1.58
1.70
1.92
1.87
1.78
1.72
1.10
0.88
1.10
1.15
1.17
1.18
1.55
1.37
1.30
0.52
0.47
0.48
0.98
0.75
0.70
0.85
0.88
0.78
0.14
0.08
0.09
0.08
0.06
0.12
0.14
0.08
0.15
0.06
0.04
0.06
0.08
0.05
0.04
0.10
0.10
0.06
0.04
0.05
0.08
0.12
0.05
0.06
0.08
0.08
0.08
3.3.3 Confirmation for most appropriate factors

of bamboo injection molding
The main effects for SN ratios and means can
be easily calculated by using the data listed in
Table 8. The results are shown in Figure 7(a)
and (b), respectively. In order to adjust the mean of
deformation to the minimal value (0 mm), any
existing adjustable factor(s) should be identified for
achieving this goal.
According to the suggested sequence and procedure of the Taguchi experimental design, improving SN ratio, adjusting the average value, and then
reducing cost are arranged in this study.
Controllable factors are categorized and listed in
Table 9, they can be easily identified based on the
results indicated by Figure 7(a) and (b). The
following steps are executed to find the most
appropriate factors of bamboo injection molding
process:
(1) Increasing the SN ratios (reduce the variation): According to the main effects plot for
SN ratios, the bamboo injection molding
process factors are designed as: A (3) B (?)
C (3) D (?) E (?).
(2) Adjusting average value to target value:
According to the main effects plot for
463
Figure 7. Main effects plot for: (a) SN ratios and (b) means.
Table 9.
The categories for controllable factors in bamboo injection molding.
Type
1
2
3
4
Purpose
Variation/target reduced
Target value adjusted
Variation reduced
Cost down
Significance for
SN ratios effect
Significance for
mean effect
Controllable
factor
Yes
No
Yes
No
Yes
Yes
No
No
A
B
C
D, E
means, the bamboo injection molding

process factors are designed as: A (3) B (1)
C (3) D (2) E (2).
For instance, the predicted results for
combination A (3) B (1) C (3) D (2) E (2) is
0.446 mm for deformation and the resulting SN
ratio is 6.47.
3.4 Verification for most appropriate factors in
bamboo injection molding process
To verify the correctness of most appropriate
factors in bamboo injection molding process for
3C electronic products, 35 testing samples processed by bamboo injection molding to measure the
averages of deformation. The results show that the
specification of deformation is 03 mm, the average
of the deformation is 0.525 mm, the standard
deviation is 0.15 mm; p 0.093 0.05, it is normally distributed, Cpk 5.25 4 1.33. The experimental results are satisfactory and meet pre-defined
specifications. The proposed approach for identifying the most appropriate combined factors in
bamboo injection molding process is able to reach
higher profit and lower cost concerning a 3C
electronic product. In addition, the proposed
approach can be implemented for on-line production immediately.
4. Conclusions
In recent years, the appearance, user-friendly
interface, and eco-environmental material of 3C
electronic product have been critical attributes to
attract customers. Electronic companies with own

brands continue to search for green materials and
eco-qualified manufacturing processes to enhance
the appearance of their products. This study
proposed a straightforward and easy-to-use
approach to solve the difficulties in bamboo
injection molding process, which is the very first
process worldwide.
The proposed approach utilizes skills such as
MSA, the Taguchi method, TRIZ, and Cpk to
provide innovative and robust thinking for solving
trade-off contradictions in bamboo injection molding. The proposed approach decides the most
appropriate factors to increase significant manufacturability and reduce the R&D time-duration in
bamboo injection molding. In the study, TRIZbased solutions (composite materials and dimensionality change) reduce the magnitude of deformation significantly. Finally, the most appropriate
of bamboo skin process parameters are identified
by using the Taguchi method. The most appropriate factors are female temperature (90 C), male
temperature (40 C), hold pressure (40), hold time
(10 s), and cold time (15 s).
The experimental results show that the proposed approach is able to solve the quality issues or
problems in bamboo injection molding. This proposed approach not only achieves attractive color
appearance for a 3C electronic product, but also
results in lower cost and desired yield rate (100%)
for further mass production as well. Same practices
could be implemented to the decorative appearance
on the surface of other 3C electronic products.
464
Acknowledgements
The TRIZ-based solutions proposed by this research
were applied to the patents at the United States, Taiwan,
and Mainland China: Taiwan Patent (no. 098135215),
Mainland China Patent (no. 200910180849.0), and the
United States Patent (no. 12/906,749).
Notes on contributors
Mu-Tsai Chang is a student of a doctors class in the
Department of Industrial Engineering and Management
at National Taipei University of Technology, Taipei,
Taiwan, R.O.C. He works at AsusTek COMPUTER
INC. and holds a chief position at the Corporate Quality
Assurance Center (CQA). His research activities include
product life-circle management, product development,
supply management, problem solving, and Six Sigma.
Chi-Hao Yeh achieved his MS degree from Iowa State
University in 1993 and PhD degree from Yuan-Zen
University in 2001. He is currently a Professor at the
Department of Industrial Engineering and Management,
NTUT, Taipei, Taiwan. His research interests include
innovative Product R&D process management, TRIZbased innovative design in engineering and management,
and E-Business in TRIZ-based evolutionary patent
searching.
References
[1] Chrysler, Ford and Motors General, Measure System
Analysis (MSA), 3rd Edn, Automotive Industry
Action Group (AIAG), USA (2002).
[2] Kane, V.E., Process capability indices, Quality
Technology, 18(1), 4152 (1986).
[3] Kotz, S. and N.L. Johnson, Process Capability

Indices, Chapman & Hall, London (1993).
[4] Lin, H.C., Using normal approximation on testing
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Chinese Institute of Industrial Engineers, 23, 111
(2006).
[5] Mann, D., S. Dewulf, B. Zlotin and A. Zusman,
Matrix 2003: Updating the TRIZ Contradiction
Matrix, CREAX Press, Belgium (2003).
[6] Michael, L.G., R. David, M. John and P. Mark, The
Lean Six Sigma Pocket Tool book, McGraw-Hill
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[7] News Release Centre, Recycled computers and
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[8] Rantanen, K. and E. Domb, Simplified TRIZ, CRC
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*
10608
3C
3C
..
:
(*
;
: Arthur_chang@asus.com)
465
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Journal of the Chinese Institute of Industrial Engineers

Vol. 29, No. 7, October 2012, 454465