Multiobjective Optimization in Quality Characteristics of Machine Made Tufted Carpet: Exploration of Utility Theory (UT) Based Approach

Abstract

Compression behavior of carpets has been a serious problem in the carpet industry for years. Carpets and rugs are mainly classified into two types as hand-made carpets and machine made carpets and there are several methodologies for measuring carpet durability such as compression and recovery characteristics, thickness loss under dynamic loading, thickness and recovery after prolonged heavy static loading, surface pile mass density factor, abrasion resistance, tuft withdrawal force etc. In this study, an attempt has been made to identify the significant factor affecting the compression behavior of machine made carpets with exploration of Utility theory (UT) based approach coupled with Taguchi robust design philosophy for quality and productivity characteristics optimization in tufted machine made carpet (Acrylic) manufactured by M-Tuft (Modra) hi-tech machine. Lower the better criteria for compression and higher the better criteria for compression recovery (%) and tuft withdrawal force, are desirable to achieve better quality of carpets. The study aims at evaluating the most favorable process environment followed by an optimal parametric setting for improved quality and productivity. Process parameters considered are Tufting speed (N), Stitch Rate (SR), Gauge size (G) and process response considered are compression recovery (%), compression (mm) and tuft withdrawal force (kgf). Taguchi design of experiments based L16 orthogonal array has been used to perform the experiments. One of the most important mechanical properties of carpet is tuft withdrawal force and compression (thickness loss). The results obtained thereof have been compared with the predicted results followed by confirmatory test.