Optimisation of shock absorber process parameters using failure mode and effect analysis and genetic algorithm


1 Department of Mechanical Engineering, Rajiv Gandhi College of Engineering and Technology, Kirumabakkam, Puducherry, 607402, India

2 Department of Mechanical Engineering, Pondicherry Engineering College, Pillaichavady, Puducherry, 605014, India

3 TENNECO Automotive India private Limited, Mettupalayam, Puducherry, 605009, India


The various process parameters affecting the quality characteristics of the shock absorber during the process were
identified using the Ishikawa diagram and by failure mode and effect analysis. The identified process parameters are
welding process parameters (squeeze, heat control, wheel speed, and air pressure), damper sealing process
parameters (load, hydraulic pressure, air pressure, and fixture height), washing process parameters (total alkalinity,
temperature, pH value of rinsing water, and timing), and painting process parameters (flowability, coating thickness,
pointage, and temperature). In this paper, the process parameters, namely, painting and washing process
parameters, are optimized by Taguchi method. Though the defects are reasonably minimized by Taguchi method,
in order to achieve zero defects during the processes, genetic algorithm technique is applied on the optimized
parameters obtained by Taguchi method.