Advanced manufacturing process of orthotic shoe insoles using a new material based on the Taguchi Methodology
A.A. Anthony (a)- P.W. Anggoro (b)*- J. Jamari (a)- A.P. Bayuseno (a)

(a) Department of Mechanical Engineering, University of Diponegoro, Jl. Prof. Soedarto, SH., Tembalang, Semarang 50275, Indonesia.

(b) Department of Industrial Engineering, Faculty of Industrial Technology, University of Atma Jaya Yogyakarta, Jl. Babarsari 44, Yogyakarta 55281, Indonesia

Abstract

Some people who have foot deformities such as diabetes often experience pain and difficulty wearing shoes. The optimization of advanced manufacturing based on CAM - CNC with EVA rubber foam material has not been optimal. Two new materials are proposed in this paper for manufacturing optimization through the experimental stage. This paper demonstrates the optimization of orthotic shoe insole manufacturing in a CNC machine so that optimal conditions for cutting parameters and material types can be obtained. The Taguchi method, Orthogonal Array L2735, PowerMill 2017, Minitab v2019, and 5 cutting parameters on CNC machines that are significant to the measured data response are used in this paper. The two new materials proposed in this paper provide very significant results when compared with EVA rubber Foam. This new material can reduce the time needed to work on one pair of insoles to 5.8 hours / pair (72.5% faster) with an average surface smoothness of 7.63 micrometer (91.49% smoother). The output of this research has significant implications for researchers and the manufacturing industry in the field of the shoe design- optimization of shoe manufacturing on CAM and CNC maching. This research also has implications for the use of modern computer-aided reverse engineering systems.

Keywords: Foot deformity- new material insole- CAM- Taguchi method

Topic: Engineering