Introduction to Design of

Experiments
 Introduction

 An experiment is a test or a series of tests.

 Experiments are used widely in the engineering
world
 Process characterization & optimization
 Evaluation of material properties
 Product design & development
 …
 “All experiments are designed experiments,
some are poorly designed, some are well-
designed”
 DOE Terminology

 Inputs/Experimental Setup
 Factors
 Treatments and levels
 Fixed and random factors.
 Outputs/Results
 Response variable
 Interaction
 Effect
 Basic DOE Principles
 Replication
 Randomization
 Blocking
 The Basic Principles of DOE

 Randomization
 Running the trials in an experiment in random order.

 Balance effects of uncontrollable variables.

 Use random number generators.

 Replication
 Sample size (improving precision of estimation, estimation of error or
background noise).
 More precision requires more work.

 Blocking
 A method to isolate controllable nuisance factors.

 Example – Fertility of different area in the same field .

 DOE Terminology

 An experimental unit is the object on which a

measurement or measurements) is taken.
 A factor is an independent variable whose values are
controlled and varied by the experimenter.
 A level is specific value of the factor (fast flow vs. slow
flow, 15 degrees vs. 30 degrees)
 A treatment is a specific combination of factor levels.
 The response is the variable being measured by the
experimenter.
 Strategies of Experimentation

• Best guess approach (trial and error)

– can continue indefinitely
– cannot guarantee best solution has been found
• One-factor-at-a-time (OFAT) approach
– inefficient (requires many test runs)
– fails to consider any possible interaction between factors
• Factorial approach (invented in the 1920’s)
– Factors varied together
– Correct, modern, and most efficient approach
– Can determine how factors interact
– Used extensively in industrial R and D, and for process
improvement.
 Types of Experimental Designs

 Single-Factor Experiment  Latin Square

 2-level (2k) Factorial  Lattice
 General full factorial  Balance Incomplete Block
 Fractional Factorial (2k-p), Design

 Response Surface Methodology  Split-Plot

(RSM)  Split-Block
 Customized Designs  Nested Designs

 Mixture Designs

 Taguchi Design
 Almost-all We Need using Minitab

Generate a worksheet of an experiment

Determine number of replication

Randomize experimental runs

Analyzing an experimental data

Graphical and Formal Assumptions Checking

Numerical and Graphical Output

 Assumptions

1. Randomness & Independence of Errors

 Independent Random Samples are Drawn for
each condition
2. Normality
 Populations (for each condition) are Normally
Distributed
3. Homogeneity of Variance
 Populations (for each condition) have Equal
Variances
Factorial Designs
 Example
A manufacturer uses primer to improve the adhesion of
automobile paint. The process improvement team wants to
determine the primer type and spray pressure level that
maximize the adhesion

The team decides to run full factorial experiment to test two

levels of spray pressure (300 Kpa, 400 Kpa) on each primer type
(Brand A, Brand B). Each combination of primer type and spray
pressure is replicated four times. Operators apply primer to an
alumunium surface using a designated spray pressure. After they
paint each specimen, they apply a finish paint and measure the
adhesive force.
 Example
1. Create a Factorial Design for the study
1. Specify factor levels
2. Change display order according to standard
3. Key in the following data for the measured Adhesion

4.52 4.55 5.05 4.88 4.48 4.37 4.89 4.75 4.29 4.43 5.14 4.91 4.60 4.25 4.95 4.71

4. Display the design according to run order, uncoded unit

2. Analyze Factorial Design
1. Reduce the model (if necessary)
2. Obtain final reduced model
3. Verify model assumptions using residual plots
4. Create Factorial (Main, Interaction, and cube plots (if applicable))
5. Try to use General Linear Model to analyze the data
 Exercise 1
A manufacturer of package cake mixes must determine the
recommended baking time and temperature to print on the
box. They want to find the factor settings that result in a
mean moisture content of 26%±1.

Food scientists replicate a full factorial design twice. They

bake all cakes in a single oven in a single day, so no
blocking variable is required. They bake the cakes for 30 or
50 minutes, at a temperature of 325 ºF or 375 ºF. The
scientists calculate moisture content by measuring the mass
of the material before and after baking.

Dataset: Cake.MPJ
 Exercise 1
Instruction:

1. Create a full FD with 2 factors, time and temperature. Replicate the

design twice.
2. Open the Project Cake.MPJ, which contains the response data
3. Fit an appropriate model to the data
4. Check the model assumptions using residual plots
5. Create factorial plots and use the Response Optimizer to determine
the best settings for time and temperature to obtain the target
moisture content of 26%, with a lower limit of 25% and upper limit
of 27%.
 Exercise 2
The yield of a chemical process is being studied. The two most important
variables are thought to be the pressure and the temperature. Three levels of
each factor are selected, and a factorial experiment with two replicates is
performed. The yield data are as follow:

Pressure
Temperature 200 215 230
90.4 90.7 90.2
150
90.2 90.6 90.4
90.1 90.5 89.9
160
90.3 90.6 90.1
90.5 90.8 90.4
170
90.7 90.9 90.1

Determine the best combination of Temperature and Pressure that maximizes

the yield
Verify the assumptions using residual plots
Investigating Power, Number of Replication and Blocking

A steel auger manufacturer cleans its product in the

final stages of production just before packaging.
Engineers have identified temperature, time, and
concentration of the cleaning solution as the key input
variables that affect the cleanliness of the augers.
After cleaning each part, experimenter soak the auger
in a solvent. The solvent is then evaporated and the
remaining residue is measured. Engineers want to
identify the process setting that produce the lowest
residue.
Investigating Power, Number of Replication and Blocking

A meaningful improvement in cleanliness is a reduction in

residue of 5 units. The standard deviation of the residue is
approximately 2 units. Determine the number of
replicates needed in a 3-factor full FD to detect a
difference of 5 units with at least 80% power.

Only 8 runs can be performed per lot of cleaning solution.

If we choose a design that requires more than 8 runs, we
must add a blocking variable that accounts for the
variation due to the different lots of cleaning solution used
in the experiment
Investigating Power, Number of Replication and Blocking

1. Determine the number of replicates needed in a 3-factor full

FD to detect a difference of 5 units with at least 80% power.
2. Adding Block to the design
3. Estimate power with 1 replicate
4. Create Factorial Design with Temperature (120, 180), Time
(10, 30 minutes), and Concentration (2, 6) and a blocking
variable (Lot 1, Lot 2)
5. Open Residue.MPJ
6. Fit appropriate model to minimize the residue in the cleaning
process
7. Once you obtained final reduced model, check assumptions
using residual plots. We will find an unusual observation
8. Investigate Observation No 10
Investigating Power, Number of Replication and Blocking

9. We discovered that run no 10 of this experiment was

incorrectly entered into Minitab. The value is
actually 44, not 64
10. Reanalyze the data using corrected observation until
we find final reduced model
11.Verify assumptions using residual plots
12.Display factorial plots, including cube plot (if
necessary)
13.Display contour and surface plots
 Exercise 1

A quality team is studying the effects of oil viscosity,

temperature, and a special on engine wear. They want to
find factor settings that minimize engine wear.

The team is looking for the treatment that produces the

least wear. To test all possible interactions, they replicate
the experiment, using two runs for each treatment. To
complete testing in half of the total time, the use two test
stands. Because the two test stands could affect the
results, the experiment should be blocked.
 Exercise 1
Instruction:

1. Open EngineWearDefine.MPJ and define the design.

2. Use Analyze Factorial Design to fit an appropriate model.
3. Evaluate appropriateness of the final model using residual
plots
4. Use factorial plots to determine the best setting
5. Try also to analyze the data using General Linear Model
 Exercise 2

The two factors that may contribute to the warping copper plates
are temperature and copper content of the plates

The current design includes 2 factors with 4 levels each. Therefore,

the total number of runs in a complete replicate is 16. To obtain an
estimate of the experimental error, use 2 replicates. Because of the
testing time is required, only 16 runs can be performed each day.
One replicate is run each day
 Exercise 2
Instruction:

1. Generate a General Full Factorial Design using Temperature

(50, 75, 100, 125) and Copper (40%, 60%, 80%, and 100%) as
factors. Because the data were collected on two separate days,
block on replicates to create a blocking variable.
2. Open the project Warp.MPJ to obtain the response data from
the experiment
3. Use Analyze Factorial Design to fit a model
4. Evaluate appropriateness of the final model using residual
plots
5. Use factorial plots to determine the settings that minimize
warping