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Design of Experiments: Taguchi Methods

By Peter Woolf (pwoolf@umich.edu) University of Michigan Michigan Chemical Process Dynamics and Controls Open Textbook
version 1.0 Creative commons

Physics, chemistry, and chemical engineering knowledge & intuition

Existing plant measurements Bayesian network models to establish connections

Patterns of likely causes & influences Efficient experimental design to test combinations of causes ANOVA & probabilistic models to eliminate irrelevant or uninteresting relationships Process optimization (e.g. controllers, architecture, unit optimization, sequencing, and utilization)

Dynamical process modeling

so it means a significant profit loss. 350. These variables can take the following values: Impellers: model A. and cooling water valve type. After examining the whole dataset of 50 variables. Your goal now is to design an experiment to systematically test the effect of each of these variables in the current reactor system.Scenario You have been called in as a consultant to find out how to optimize a client’s CSTR reactor system to both minimize product variation and also to maximize profit. How should we design our experiment? . motor speed for the mixer. PI. you conclude that the most likely four variables for controlling profitability are the impeller type. control algorithm. B. or 400 RPM Control algorithm: PID. or C Motor speed for mixer: 300. or P only Cooling water valve type: butterfly or globe Each time you have to change the system setup. you have to stop much of the plant operation.

400. B C. 400. or P only Cooling water valve type: butterfly or globe Option 1: Factorial design to test all possible combinations A. 350. 400. 350. 350. 400.PI.PID. 350.PI. PI.PID. G Total experiments= (3 impellers)(3 speeds)(3 controllers)(2 valves)=54 Can we get similar information with fewer tests? How do we analyze these results? . G B. G A.PID. 400.PID. 350. B C. B C. 350. G A. 400.PID.P. B B. B B. 350.P. B C.PI.PI.PI. 400. 350.PID. G C. B A. G C. 300. G C.P. B A.PI. 300. 350. B A. G B. 400. 400.PI. G A. 350. 300. B. or 400 RPM Control algorithm: PID. or C Motor speed for mixer: 300.P. 300. G B. 400. 300. 400. B A.PI.PI. G B. G A. G A. 400. 400. B B. 400. B B. B C. 300.P. G C. 350. G C. B A. G C.PID. 350. B B.PI.Scenario These variables can take the following values: Impellers: model A.P. G A. B A.P. B A. G B.PI. B B. B B. 300. G C. 300. 350. G A.P.P.PID. 300.PID.P. 350.PID. B B. B A.PI. 350.P. B C.PI. G B.PI. B C.PID. 300. 350. B C.P.PID.P.PID.PID.PID.P. B B. 400. 400.PI. 300. G C. B A.PI.PI.PID.P. 400. 300. 300.P. G B. 300.PI. G C.P. 350. 300. 300.PID. 350. G B. 350. 400. 300.P. G B. 300.PID. G A. B C.

. PI. Example: L9 orthogonal array Key Feature: Compare any pair of variables (P1. 350.Scenario These variables can take the following values: Impellers: model A. and P4) across all experiments and you will see that each combination is represented. or P only Cooling water valve type: butterfly or globe Option 2: Taguchi Method of orthogonal arrays Motivation: Instead of testing all possible combinations of variables. we can test all pairs of combinations in some more efficient way. B. or C Motor speed for mixer: 300. P2. or 400 RPM Control algorithm: PID. P3.

Example: L36 array Each pair of combinations is tested at least once Factorial design: 323=94.827 experiments Taguchi Method with L36 array: 36 experiments (~109 x smaller) .178.Option 2: Taguchi Method of orthogonal arrays Arrays can be quite complicated.143.

Option 2: Taguchi Method of orthogonal arrays Where do we these arrays come from? 1) Derive them • Small arrays you can figure out by hand using trial and error (the process is similar to solving a Sudoku) • Large arrays can be derived using deterministic algorithms (see http://home.net/~gsherwood/cover.att.att.com/~njas/oadir/index.html How do we choose a design? The key factors are the # of parameters and the number of levels (states) that each variable takes on. .htm for details) 2) Look them up • Controls wiki has a listing of some of the more common designs • Hundreds more designs can be looked up online on sites such as: http://www.research.

Scenario These variables can take the following values: Impellers: model A. or P only Cooling water valve type: butterfly or globe Option 2: Taguchi Method of orthogonal arrays # parameters: Impeller. valve = 4 # levels: 3 3 3 2 = ~3 Experiment Impeller A A A B B B C C C L9 Motor Speed 300 350 400 300 350 400 300 350 400 Control PID PI P PI P PID P PID PI Valve BF G G BF BF G G BF BF 1 2 3 4 5 6 7 8 9 No valve type 3. or C Motor speed for mixer: 300. algorithm. or 400 RPM Control algorithm: PID. 350. speed. PI. B. so this entry is filled at random in a balanced way .

then each is chosen with 0.org/xpls/abs_all. 350.33 probability) Random designs tend to work poorly for small experiments (fewer than 50 variables). or C Motor speed for mixer: 300. PI.g if there are 3 states.pdf http://ieeexplore. randomly assigning experimental conditions will with high probability create a near optimal design.csail.edu/drl/journal_club/papers/CS2-Candes-Romberg-05. but work well for large systems.ieee. or P only Cooling water valve type: butterfly or globe Option 3: Random Design: Surprisingly.mit.Scenario These variables can take the following values: Impellers: model A. or 400 RPM Control algorithm: PID. B.jsp?arnumber=1614066 . For more information on these methods see the following resources http://groups. • Choose the number of experiments to run (this can be tricky to do as it depends on how much signal recovery you want) • Assign to each variable a state based on a uniform sample (e.

PI. 350. B. or 400 RPM Control algorithm: PID. or C Motor speed for mixer: 300.Scenario These variables can take the following values: Impellers: model A. or P only Cooling water valve type: butterfly or globe When do we use which method? Option 1: Factorial Design Small numbers of variables with few states (1 to 3) Interactions between variables are strong and important Every variable contributes significantly Option 2: Taguchi Method Intermediate numbers of variables (3 to 50) Few interactions between variables Only a few variables contributes significantly Option 3: Random Design Many variables (50+) Few interactions between variables Very few variables contributes significantly .

8 17.1 1) Plot the data and look at it 2) ANOVA 1-way: effect of impeller 2-way: effect of impeller and motor speed Test multiple combinations .1 17.1 17.2 15. or P only Cooling water valve type: butterfly or globe Once we have a design. B. PI.Scenario These variables can take the following values: Impellers: model A. 350.0 16. or 400 RPM Control algorithm: PID.9 16. how do we analyze the data? Expt. or C Motor speed for mixer: 300. 1 2 3 4 5 6 7 8 9 Impeller A A A B B B C C C Motor Speed 300 350 400 300 350 400 300 350 400 Control PID PI P PI P PID P PID PI Valve BF G G BF BF G G BF BF Yield 16.9 19.2 18.

0 16.2 15. PI.1 17. or 400 RPM Control algorithm: PID.1 3) Bin yield and perform Fisher’s exact test or Chi squared test to see if any effect is significant .Scenario These variables can take the following values: Impellers: model A.9 19. or P only Cooling water valve type: butterfly or globe Once we have a design.8 17. how do we analyze the data? Expt.9 16. B.2 18. or C Motor speed for mixer: 300. 350. 1 2 3 4 5 6 7 8 9 Impeller A A A B B B C C C Motor Speed 300 350 400 300 350 400 300 350 400 Control PID PI P PI P PID P PID PI Valve BF G G BF BF G G BF BF Yield 16.1 17.

"Optimizing a PU formulation by the Taguchi Method. . (polyurethane quality control). Sohelia R." Plastics Engineering 46. Sutej. and Joseph M.n2 (Feb 1990): 23(5). some of which involve poorly understood physics or chemistry.Field case study: Polyurethane quality control Polyurethane manufacturing involves many steps.. Three dominant factors of product quality are: 1) Water content 2) Chloroflourocarbon-11 (CFC-11) concentration 3) Catalyst type Case modified from Lunnery.

.12 Case modified from Lunnery. Sohelia R.2.B.5 25.3. and Joseph M.35 11." Plastics Engineering 46.C. D 1. wt% Isocyanate type # factors 4 5 3 2 2 2 Description A. Sutej. S2. (polyurethane quality control).5 S1. .Field case study: Polyurethane quality control Factors and Levels Polyol type Catalyst package Surfactant type Water. wt% CFC-11. "Optimizing a PU formulation by the Taguchi Method.4. 1.5.n2 (Feb 1990): 23(5). S3 0.

" Plastics Engineering 46. "Optimizing a PU formulation by the Taguchi Method. .. (polyurethane quality control).n2 (Feb 1990): 23(5). Sutej. and Joseph M.Field case study: Polyurethane quality control Experiment design using a modified L16 array A 3 S2 25 11 B 1 S2 35 12 C 3 S1 35 12 D 1 S1 25 11 B 3 S1 25 12 A 2 S1 35 11 D 3 S2 35 11 C 2 S2 25 12 B 3 S3 25 11 A 4 S3 35 12 D 3 S2 35 12 C 4 S2 25 11 A 3 S2 25 12 B 5 S2 35 11 C 3 S3 35 11 D 5 S3 25 12 Design modified from an L25 array to better account for the number of states of each variable. Sohelia R. Note not all pairs involving catalyst are tested--this is even sparser Case modified from Lunnery.

followed by linear regression to identify optimal conditions Case modified from Lunnery. final rise height. Sohelia R. and flow ratio were determined in a flow tube. . Sutej.." Plastics Engineering 46. "Optimizing a PU formulation by the Taguchi Method. Height of rise at gel.Field case study: Polyurethane quality control Experimental Procedure: Reactivity profile and friability (subjective rating) were determined from hand-mix foams prepared in 1-gal paper cans. and Joseph M.n2 (Feb 1990): 23(5). Data Analysis ANOVA to identify significant factors. (polyurethane quality control). Free rise densities were measured on core samples of open blow foams.

What do you do? . Just before you are to ship the oil. One barrel of sesame oil sells for $1000.Extreme Example: Sesame Seed Suffering You have just produced 1000x 55 gallon drums of sesame oil for sale to your distributors. one of your employees remembers that one of the oil barrels was temporarily used to store insecticide and is almost surely contaminated. Unfortunately. all of the barrels look the same. while each assay for insecticide in food oil costs $1200 and takes 3 days. Tests for insecticide are extremely sensitive.

6 -> Sample B -.7 -> Sample C -.Extreme Example: Sesame Seed Suffering Solution: Extreme multiplexing.3.4 --> Sample A -.-.2.+ 2 3 4 5 6 7 8 poison barrel 8 Result: Using only 3 tests 4 you can uniquely identify 6 the poison barrel! 7 2 3 5 1 .+.+.5.+ +.-.-.2.+.B.+. Like Taguchi methods but optimized for very sparse systems Example solution w/ 8 barrels Mix samples from each 1 barrel and test mixtures A.+ -.-.C Mix 1.+.5.Mix 1.+.Mix 1.+ Is this enough tests? +.3.

000.000. Like Taguchi methods but optimized for very sparse systems Solution w/ 1000 barrels Mix samples from each 1 2 3 barrel and test mixtures Experiments required=Log2(1000)=~10 Solution w/ 1.Extreme Example: Sesame Seed Suffering Solution: Extreme multiplexing.000 barrels Experiments required=Log2(1.000)=~20 Optimal experiments can be extremely helpful! 4 5 6 7 8 .

• Taguchi and random designs often perform better depending on size and assumptions. but can be impractically large.Take Home Messages • Efficient experimental design helps to optimize your process and determine factors that influence variability • Factorial designs are easy to construct. .

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