Series F

TQM Training Module on

Response Surface Method
Doc. No. F-11.02.20180421
Revision 02; 21st April 2018
Authors: Pankaj Lochan

For further clarifications, write to pankaj.lochan@jsw.in © Total Quality Management, JSW Group
 TQM Training Series: 6 series with 66 training modules
This is a training module on Response Surface Method (F-11)
Series-A Series-C Series-D Series-F
Basic Problem Solving Tools Quality Management Basics Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Value Stream Mapping (VSM) F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Time & Motion Study F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 SMED F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Wrench Time Analysis F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 Queuing Theory F-05 Factorial DoE
A-06 Check Sheets C-06 Strategic Analysis Tools D-06 Inventory Management F-06 Principal Component Analysis
A-07 Histogram C-07 Policy Management D-07 Linear Programming Problem F-07 Cluster Analysis
C-08 Policy Diagnosis F-08 Conjoint Analysis
A-08 Pareto Charts D-08 Game Theory
C-09 Daily Management F-09 Discriminant Analysis
A-09 Graphs D-09 OEE
C-10 Daily Mgmt. in Maintenance F-10 Factor Analysis
D-10 PERT & CPM
Series-B C-11 Cross Functional Mgmt. F-11 Response Surface Method
C-12 Quality Assurance Basics
Basic Management Tools F-12 Taguchi DoE
C-13 MSA
B-01 Brainstorming Series-E F-13 Weibull Analysis
C-14 PFD, FMEA, Control Plan
B-02 Affinity Diagram Decision-making Tools
C-15 Cost of Poor Quality (COPQ)
B-03 Arrow Diagram C-16 Improvement Fundamentals E-01 Quality Function Deployment
B-04 Tree Diagram C-17 4i Methodology E-02 Fault Tree Analysis
B-05 PDPC C-18 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram C-19 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis C-20 QC Story Approach E-05 Time Series Analysis
B-08 Relation Diagram C-21 Kaizen, OPL, Poka Yoke
DEFINITION

A designed experiment is a systematic approach of doing series of runs, or tests, in which you
purposefully make changes to input variables at the same time and observe the responses.

Design of Experiments

Factorial RSM Taguchi Mixture

Screening Optimization
2 level
Experiments Experiments Central Simplex Centroid
Composite 3 level
2 >2 Design
levels levels 4 level
Simplex Lattice
2-level fractional Box-Bhenken 5 level
2- level Split-Plot
factorial Design
General Model Mixed level

2-level Placket- 2- level full Extreme Vertices

Burman 3 factorial
WHY RESPONSE SURFACE METHOD

In Factorial DOE, we saw that there was a linear relationship between

the factors and the response.

But

What if there isn’t a Linear Relationship ?

Is it always reasonable to assume there is a linear relationship between
the factors and the response ?

If these thoughts come to your mind, then Response Surface Designs

are the right tool to optimize your process.
CENTRAL COMPOSITE DESIGN
(CCD)

A central composite design is the most commonly used response surface designed
experiment. Central composite designs are a factorial or fractional factorial design with centre
points, augmented with a group of axial points (also called star points) that let you estimate
curvature.

Most Popular classes of RSM designs due to following three properties:

• A CCD can be run sequentially. It can be naturally partitioned into two subsets of points,
the first subset estimates linear and two factor interaction effects while the second subset
estimates curvature effects. The second subset need not be run when analysis of the data
form the first subset points indicates the absence of significant curvature effects.

• Very efficient, providing much information on experiment variable effects and overall
experimental error in a minimum number of required runs.

• Very flexible, the availability of several varieties of CCDs enables their use under different
experimental regions of interest and operability
TYPES OF CCD

Alpha (α) is the distance of each axial point (also called star
point) from the centre in a CCD.

1 2 3
Centre Points: To
detect curvature

Axial Points or Star Cube Points: To

Points: To estimate estimate linear and
quadratic terms interaction effect.

Rotatable CCD Face Centred CCD Inscribed CCD

When, α > 1, Axial points or Star
points are outside the cube
• Does testing at five levels
• Cube points are at the design limits
• Star points are at some distance from the centre
depending on the number of factors in the design
• 6
High quality predictions over the entire design
space, but care must be taken when deciding on the
factor ranges. Especially, it must be sure that also
the star points remain at feasible (reasonable)
levels.
When, α = 1, Axial points or Star points
are on the face of cube
• Relatively high quality predictions over
the entire design range, but poor
precision for estimating pure quadratic
coefficients.
• Do not require using points outside the
original factor range.
When, α < 1, Axial points or Star points are
outside the cube
• Uses only points within the factor
ranges originally specified, so the
prediction space is limited
compared Type 1
EXAMPLE

You are working as a Material Specialist in a Polymer Manufacturing Unit. Your team
is given a task to create a polymer, a kind of plastic that has a quality characteristic of
Elasticity.
Your team has identified three factors viz:
Factor A and B, the ingredients which make up the polymer and
Factor C is the temperature
And the Response is Elasticity.

• Total Number of Factors = 3

• Levels for each factor = 2
• Total Number of Corner Points = 2^3 = 8
• Total Number of Star Points = 2* No of factors = 2*3 = 6
• Total number of centre points based on choice, for our
example let us take 2 centre points.

• Number of Axial Points in a CCD = 2*k, where k is number of factors.

• Recommended distance α of axial points from the centre = (NF)^1/4. Where, NF is the
number of points in factorial portion from the centre.
CREATING DESIGN
Stat > DOE > Response Surface > Create
Response Surface Design
Select the Type of Design, for this example
let us select Central Composite.
Select number of continuous and
categorical factors , in our case we have
three continuous factors.
Click on Designs.
CREATING DESIGN

Select the Total No.

of Blocks and
Centre Points to be
added in Cube and
Axial.

Select options based on Input factor name and

choice of your design levels
and Click OK Click OK till last.
UNDERSTANDING THE DESIGN
PLAN- SESSION WINDOW

Indicates the number Number of replicates

of factors added

Factors: 3 Replicates: 1
Base runs: 20 Total runs: 20
Base blocks: 1 Total blocks: 1

Two-level factorial: Full factorial

Total No. of Corner Points or Cube
Cube points: 8
Points = (level ^ factors)
Centre points in cube: 6
Total No. of Axial Points or Cube
Axial points: 6 Points = (level ^ factors)
Centre points in axial: 0

α: 1.68179
α (distance of axial
points from the
centre) = Nf^(1/4)
UNDERSTANDING THE DESIGN
PLAN- SESSION WINDOW

Std Order and Run Order are in

same order, this means there is no
Factorial Points or Cube randomization, this allows to do the
Points experiments in sequential manner.

It can be naturally partitioned into

two subsets of points, the first
subset(cube points) estimates linear
and two factor interaction effects
Axial Points
While the second subset(Axial
points and Centre Points) estimates
curvature effects.

Centre Points The second subset need not be run

when analysis of the data form the
first subset points indicates the
absence of significant curvature
effects
RESPONSE FILLED SHEET

Experiments were
performed
according to the
prescribed
treatment.

Only two experiments

were conducted at centre
point, hence there is a star
marked against rest.
ANALYZING THE DESIGN

1. Select Response column

(in our case Y-elasticity)

2. Click on Terms

1. Select Full Quadratic.

2. Select all terms.
3. Click OK
Stat > DOE > Response Surface > Analyse Response 4. Click on Graphs, Select
Surface Design Four in One. Click OK till
the end.
INTERPRETING OUTPUT

Model Summary

S R-sq R-sq(adj) R-sq(pred)

2.63173 97.22% 93.04% 78.42%

Coded Coefficients

Term Effect Coef SE Coef T-Value P-Value VIF

Constant 57.31 1.74 32.92 0.000
Linear Terms used to estimate A 3.000 1.500 0.658 2.28 0.063 1.00
Main effects B -4.260 -2.130 0.658 -3.24 0.018 1.00
C 3.620 1.810 0.658 2.75 0.033 1.00
Quadratic Terms to A*A -9.380 -4.690 0.658 -7.13 0.000 1.50
B*B -12.540 -6.270 0.658 -9.53 0.000 1.50
All the terms are significant,
estimate Curvature C*C -10.420 -5.210 0.658 -7.92 0.000 1.50 Only linear effect of factor A is
A*B -14.260 -7.130 0.930 -7.66 0.000 1.00
Cross-Term of the order 2 to
A*C -6.540 -3.270 0.930 -3.51 0.013 1.00
insignificant.
estimate 2-way interactions. B*C -5.460 -2.730 0.930 -2.93 0.026 1.00

Regression Equation in Uncoded Units

Y-elasticity = 57.31 + 1.500 A - 2.130 B + 1.810 C - 4.690 A*A -

6.270 B*B - 5.210 C*C - 7.130 A*B - 3.270 A*C - 2.730 B*C
RESIDUAL PLOTS

Interpretation
same as earlier
cases.
MAIN EFFECTS & INTERACTION
PLOT
Main Effects Plot for Y-elasticity
Fitted Means
A B C
60

55
Mean of Y-elasticity

50

45

40

35

30

25

-2 0 2 -2 0 2 -2 0 2

We can clearly see, all the factor exhibit a non linear main
effect. (Interpretation is same as in previous cases)
Inference should not be
Caution
derived from main effect
plots when interactions are
significant.
In interaction A*B, clearly observable that if we keep A at
lower level and increase level of B, the elasticity increases.
Further, If we keep B constant at low level and increase A,
we see an increase in elasticity, but when we keep B
constant at higher level, and increase A, there is a decrease
in Elasticity.
 CONTOUR PLOT AND RESPONSE
OPTIMIZER

Contour Plots of Y-elasticity

B*A C*A Y-elasticity
2 2
< -10
-10 – 0
1 1
0 – 10
10 – 20
0 0 20 – 30
30 – 40
-1 -1 40 – 50
> 50
-2 -2 Hold Values
Contour
-2 Plots
-1 of0Y-elasticity
1 2 -2 -1 0 1 2
A 0
B*A C*B C*A Y-elasticity B 0
2 2 2
< -10 C 0
-10 – 0
1 1
0 – 10
1
10 – 20
0 0 20 – 30

-1
0 -1
30 – 40
40 – 50
Interpretation is same as in previous cases
> 50
-2 -2
-2 -1 0 -11 2 -2 -1 0 1 2
Hold Values
A 0
C*B B 0
2
-2 C 0

1
-2 -1 0 1 2

-1
EXAMPLE: ANALYZING DESIGN

The experiment uses three factors - nitrogen, phosphoric acid, and potash - all
ingredients in fertilizer. The effect of the fertilizer on snap bean yield was studied in a
central composite design.

The actual units for the -1 and +1 levels are 2.03 and 5.21 for nitrogen, 1.07 and
2.49 for phosphoric acid, 1.35 and 3.49 for potash. Data is in file CCD_EX1
BOX BEHNKEN DESIGN

Centred on the edges of the cube,

equidistant from the centre.

at the centre
of the design

Key features of this design include:

· Allow efficient estimation of quadratic terms in a regression model

· Exhibits the desirable properties of having orthogonal blocks and being rotatable or nearly rotatable
· Usually consists of fewer design points and therefore are less expensive to run than central
composite designs
· All design points fall within safe operating limits (within the nominal high and low levels) for the
process
· Minimum three factors are required to design Box-behnken design
EXAMPLE

Suppose you have a process for pressure treating utility poles with creosote. In the treating step of
the process, you place air-dried poles inside a treatment chamber. The pressure in the chamber is
increased and the chamber is flooded with hot creosote. The poles are left in the chamber until they
have absorbed 12 pounds of creosote per cubic foot. You would like to experiment with different
settings for the pressure, temperature of the creosote, and time in the chamber. Your goal is to get
the creosote absorption as close to 12 pounds per cubic foot as possible, with minimal variation.
Previous investigation suggests that the response surface for absorption exhibits curvature.

Creosote The chamber will withstand internal pressures up to 220 psi, although the strain on equipment is
pronounced at over 200 psi. The current operating value is at 175 psi, so you feel comfortable with a
range of values between 150 and 200. Current operating values for temperature and time are 210
degrees F and 5 hours, respectively. You feel that temperature cannot vary by more than 10° from
the current value. Time can be varied from 4 to 6 hours.

Utility Poles
A Box-Behnken design is a practical choice when you cannot run all of the factors at their high (or low)
levels at the same time. Here, the high level for pressure is already at the limit of what the chamber can
handle. If temperature were also at its high level, this increases the effective pressure, and running at
these settings for a long period of time is not recommended. The Box-Behnken design will assure that
no runs require all factors to be at their high settings simultaneously
CREATING BOX- BEHNKEN
DESIGN

Stat > DOE > Response Surface > Select Box-Behnken

Create Response Surface Design (Here, minimum no of continuous factors
required is 3.)
Click Design
CREATING BOX- BEHNKEN
DESIGN

Input the factor

information such
as Name and
Levels.

You can custom add the no. of centre points,

however it is recommended to have minimum
number of 3 centre points in design.
Click OK, Click Factors
Select Summary
Table and design
Table. Click OK till
the end.
GENERATED DESIGN

Factors: 3 Replicates: 1
Base runs: 15 Total runs: 15
Base blocks: 1 Total blocks: 1
Centre points: 3

Design Table (randomized)

Run Blk A B C
1 1 0 1 1
2 1 -1 0 1 When you perform the
3 1 0 -1 1 experiment, use the order that
4 1 1 1 0 is shown to determine the
5 1 1 -1 0 conditions for each run. For
6 1 -1 -1 0 example, in the first run of your
7 1 1 0 -1 experiment, you would set the
8 1 0 -1 -1 pressure at 175 psi (0 =
9 1 0 0 0 centre), the temperature at
10 1 0 0 0 210°F (0 = centre), and treat
11 1 -1 1 0 the utility poles for 5 hours (0 =
12 1 0 1 -1 centre). None of the treatment is set at
13 1 1 0 1 PtType: 2 stands for edge
all high value. This is one of
centroid point
14 1 -1 0 -1 0 stands for centre point
special characteristic of Box-
15 1 0 0 0 Behnken Design
EXAMPLE: DOE BOX BEHNKEN

You are working in a chemical industry, you are optimizing viscosity (higher the better) of a
chemical your previous analysis shows that there are three factors which influence your
response Temperature, Pressure and Agitation Rate. It is known that curvature is significant.
Further due to safety constraints you cannot run your process by keeping factors at High
levels simultaneously. Conduct a design of experiment and obtain the desired result.

Levels for Factors:

1. Temperature: 150 and 200

2. Agitation Rate: 5 and 10
3. Pressure: 15 and 25
DATA FOR RESPONSE

Please ensure your

data is ordered in
Standard Order
before copying
down the Response
(y1).

Analyse and share

your results.
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