The powder coating is an economic, technologically superior and environment friendly painting technique compared with other conventional painting methods. However large variation in coating thickness can reduce the attractiveness of powder coated products. The coating thickness variation can also adversely affect the surface appearance and corrosion resistivity of the product. This can eventually lead to customer dissatisfaction and loss of market share. In this paper, the author discusses a dual response surface optimization methodology to minimize the thickness variation around the target value of powder coated industrial enclosures. The industrial enclosures are cabinets used for mounting the electrical and electronic equipment. The proposed methodology consists of establishing the relationship between the coating thickness & the powder coating process parameters and developing models for the mean and variance of coating thickness. Then the powder coating process is optimized by minimizing the standard deviation of coating thickness subject to the constraint that the thickness mean would be very close to the target. The study resulted in achieving a coating thickness mean of 80.0199 microns for industrial enclosures, which is very close to the target value of 80 microns. A comparison of the results of the proposed approach with that of existing methodologies showed that the suggested method is equally good or even better than the existing methodologies. The result of the study is also validated with a new batch of industrial enclosures.

The controlling of bug fixing process during the system testing phase of software development life cycle is very important for fixing all the detected bugs within the scheduled time. The presence of open bugs often delays the release of the software or result in releasing the software with compromised functionalities. These can lead to customer dissatisfaction, cost overrun and eventually the loss of market share. In this paper, the authors propose a methodology to quantitatively manage the bug fixing process during system testing. The proposed methodology identifies the critical milestones in the system testing phase which differentiates the successful projects from the unsuccessful ones using Mahalanobis Taguchi system. Then a model is developed to predict whether a project is successful or not with the bug fix progress at critical milestones as control factors. Finally the model is used to control the bug fixing process. It is found that the performance of the proposed methodology using Mahalanobis Taguchi system is superior to the models developed using other multi-dimensional pattern recognition techniques. The proposed methodology also reduces the number of control points providing the managers with more options and flexibility to utilize the bug fixing resources across system testing phase. Moreover the methodology allows the mangers to carry out mid- course corrections to bring the bug fixing process back on track so that all the detected bugs can be fixed on time. The methodology is validated with eight new projects and the results are very encouraging.

The performance of a product is generally characterized by more than one response variable. Hence the management often faces the problem of simultaneous optimization of many response variables. This study was undertaken to simultaneously optimize the surface hardness and case depth of carbonitrided bushes. Even though lots of literature has been published on various methodologies for tackling the multi-response optimization problem, the simultaneous optimization of heat treated properties of carbonitrided bushes are not reported yet. In this research the effect of four factors and two interactions on surface hardness and case depth of carbontirded bushes were studied using design of experiments. Based on the experimental results, the expected values of the heat treated properties of the bushes were estimated for all possible combination of factors. Then the best combination which, simultaneously optimized the response variables, was arrived at using desirability function. The study showed that the optimum combination obtained through desirability function approach not only minimized the variation around the targets of surface hardness and case depth but also was superior to the ones obtained by optimizing the response variables separately. Moreover this study provides a useful and effective approach to design the production process to manufacture bushes with customer specified surface hardness and case depth targets.

As the need for software increased, the number of software firms and the competition among them also increased. The software companies in developing countries like India can no longer survive based on cost advantage alone. The firms need to deliver competitively priced quality software products on time. This can be achieved through quantitatively managing the different phases or sub processes in software development process. But quantitative management of a process consisting of a set of interlinked sub processes or stages with the output of one sub pro-cess influencing that of subsequent stages and final output is not easy. The process performance models developed for quantitative management of software development process often model the final outcome in terms of factors from various stages together or focuses only on quantitatively managing a particular sub process independently. In manufacturing and other engineering indus-tries, the processes with multiple sub process are monitored and controlled using multistage pro-cess control methodology. This paper is an application of multistage statistical process control for managing the software development process. The suggested methodology is a combination of process performance models and control charts. The proposed methodology can be easily im-plemented for controlling various types of software projects like development projects, incre-mental development projects, testing projects etc. The methodology also provides the project manager the opportunity to tighten or relax the control at various sub processes based on the pro-ject team’s strengths and still achieve the goal on the final outcome.