MIE364H1S

Methods of Quality Control and Improvement

Course Instructor: Prof. V. Makis
Handout #6

Factorial Design: 4 Factors, Each at 2 Levels, n = 1.

A milling operation was evaluated for finish milling of a particular part. The critical
controllable factors affecting surface finish were identified as:
A = cutting speed (80, 100)
B = depth of cut (1, 8)
C = cutter diameter (100, 200)
D = feed per tooth (0.25, 0.65)
For this experiment, smaller values are better (smoother).
Factorial Design
Full Factorial Design
Factors:
Runs:
Blocks:

4
16
none

Base Design:
Replicates: 1
Center pts (total):

4, 16
1
0

All terms are free from aliasing

Fractional Factorial Fit

Estimated Effects and Coefficients for Y (coded units)
Term
Effect
Constant
A
-14.5
B
9.5
C
3.5
D
2.25
A*B
1.5
A*C
1
A*D
-1.75
B*C
2
B*C
-0.75
C*D
-17.75
A*B*C
2.5
A*B*D
-3.75
A*C*D
1.75
B*C*D
21.75
A*B*C*D -16.75

Coef
69.75
-7.25
4.75
1.75
1.125
0.75
0.5
-0.875
1
-0.375
-8.875
1.25
-1.875
0.875
10.875
-8.375

Analysis of Variance for Y (coded

units)
Source
Main Effects
2-Way Interaction
3-Way Interaction
4-Way Interaction
Residual Error
Total

DF
4
6
4
1
0
15

Seq
SS
1271
1304
1986
1122
0
5683

Adj
SS
1271
1304
1986
1122
0

Adj MS
317.8
217.3
496.4
1122.3
0

F
*
*
*
*

P
*
*
*
*

Data Display
Row
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

A
-1
1
-1
1
-1
1
-1
1
-1
1
-1
1
-1
1
-1
1

B
-1
-1
1
1
-1
-1
1
1
-1
-1
1
1
-1
-1
1
1

C
-1
-1
-1
-1
1
1
1
1
-1
-1
-1
-1
1
1
1
1

D
-1
-1
-1
-1
-1
-1
-1
-1
1
1
1
1
1
1
1
1

Y
42
44
86
60
103
65
69
80
101
70
74
67
46
49
95
65

Yates Algorithm
24 design, n = 1, N = 16
A

(i)

(ii)

(iii)

(iv)

(1)

42

86

232

549

1116

44

146

317

567

-116

86

168

312

-51

76

ab
c
ac
bc
abc
d
ad
bd
abd

+
+
+
+
+

+
+
+
+
+

+
+
+
+
-

+
+
+
+

60
103
65
69
80
101
70
74
67

149
171
141
95
160
2
-26
-38
11

255
-24
-27
-38
-27
60
-19
-30
65

-65
41
35
21
-9
85
-57
-3
11

12
28
8
16
20
18
-14
-6
-30

effect
= 69.75

A = -14.5
B = 9.5
AB = 1.5
3.5
1
2
2.5
2.25
-0.175
-0.75
-3.75

SS

F=SS/MSE
77841
841
361
9
49
4
16
25
20.25
12.25
2.25
56.25

FA =26.98 *
FB =11.58 *

cd
acd

+
+

+
+

46
49

-31
-7

-28
49

-79
95

-142
14

-17.75
1.75

1260.25
12.25

FCD =40.43 *

bcd

95

24

77

174

21.75

1892.25

abcd

65

-30

-33

-57

-134

-16.75

1122.25

FBCD =60.7 *
FABCD =36 *

Normal Probability Plot of the Effects

(response is Y, Alpha = .05)
99
BCD

95
90

F actor
A
B
C
D

Percent

80
70
60
50
40
30
20

10

ABC D

5
1

CD

-20

-10

0
Effect

Lenth's PSE = 2.8125

TSS = 83524
TCSS = 5683 = TSS SS( )
SSE = SS(ABC) + SS(ABD) + SS(ACD) = 93.5
MSE = SSE/3 = 31.17
F0.05,1,3 = 10.13.

10

Effect Ty pe
Not Significant
Significant

20

N ame
A
B
C
D