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Designing Experiments
Designing Experiments
Graphical Analysis
DOE Methodology
80
Pressure (psi)
135 85
6
130
125
1 2 3 4
90
5
Designing Experiments
95
120 7
30 31 32 33 34 35
Temperature (C)
Improve Phase
Designing Experiments
Designing Experiments
Welcome to Improve
DOE Methodology
Wrap Up & Action Items
SIPOC
VOC
Project Scope
Fractional Factorial
(X5) (X3) Full Factorial
Center Points
(X11)
(X4)
The Analyze Phase narrowed down the many inputs to a critical few now it is necessary
to determine the proper settings for these few inputs because:
– The vital few potentially have interactions.
– The vital few will have preferred ranges to achieve optimal results.
– Confirm cause and effect relationships among factors identified in Analyze Phase (e.g.
Regression)
Understanding the reason for an experiment can help in selecting the design and
focusing the efforts of an experiment.
Reasons for experimenting are:
– Problem Solving (Improving a process response)
– Optimizing (Highest yield or lowest customer complaints)
– Robustness (Constant response time)
– Screening (Further screening of the critical few to the vital few X’s)
Problem Solving
– Eliminate defective products or services.
– Reduce cycle time of handling transactional processes.
Optimizing
– Mathematical model is desired to move the process response.
– Opportunity to meet differing customer requirements (specifications or VOC).
Robust Design
– Provide consistent process or product performance.
– Desensitize the output response(s) to input variable changes including NOISE
variables.
– Design processes knowing which input variables are difficult to maintain.
Screening
– Past process data is limited or statistical conclusions
prevented good narrowing of critical factors in Analyze
Phase.
What are the differences between DOE modeling and physical models?
– A physical model is known by theory using concepts of physics, chemistry,
biology, etc...
– Physical models explain outside area of immediate project needs and include
more variables than typical DOE models.
– DOE describes only a small region of the experimental space.
The objective is to
minimize the response.
The physical model is
not important for our
business objective. The
DOE Model will focus in
the region of interest.
DOE allows the experimenter to study the effect of many input variables that
may influence the product or process simultaneously, as well as possible
interaction effects (for example synergistic effects).
Y = f (x)
The goal of DOE is to find a design that will produce the information required at
a minimum cost.
One Factor at a Time (OFAT) is an experimental style but not a planned experiment
or DOE.
The graphic shows yield contours for a process that are unknown to the experimenter.
7 120 33 90
135 85
6
130 90
1 2 3 4 5 Optimum identified
125
95
with OFAT
120 7
– Full Factorials
• 2-5 input variables
Response
Surface
Full Factorial
Fractional Factorials
The general notation used to designate a full factorial design is given by:
2k
– Where k is the number of input variables or factors.
– 2 is the number of “levels” that will be used for each factor.
• Quantitative or qualitative factors can be used.
4 1 1 -1 1.50
5.15 2.4
5 -1 -1 1 5.15
6 1 -1 1 2.40
Fulcrum
7 -1 1 1 8.20
8 1 1 1 4.55
2.1 Start Angle 0.9
What are
these?
Catapult.mtw
This graph is used to see the relative effect of each factor on the
output response.
Stat>DOE>Factorial>Factorial Plots … Main Effects, select response and factors
Hint: Check
the slope!
Which factor has the
largest impact on the
output?
Avg Distance at Low Setting of Start Angle: 2.10 + 3.35 + 5.15 + 8.20 = 18.8/4 = 4.70
Main Effects Plot (data means) for Distance
-1 1 -1 1 -1 1
5.2
4.4
Dist
3.6
2.8
2.0
Start Angle Stop Angle Fulcrum
Avg. distance at High Setting of Start Angle: 0.90 + 1.50 + 2.40 + 4.55 = 9.40/4 = 2.34
Run # Start Angle Stop Angle Fulcrum Distance
1 -1 -1 -1 2.10
2 1 -1 -1 0.90
3 -1 1 -1 3.35
4 1 1 -1 1.50
5 -1 -1 1 5.15
6 1 -1 1 2.40
7 -1 1 1 8.20
8 1 1 1 4.55
Higher
B-
Y When B changes
from low to high,
Output the output drops
dramatically.
When B changes B+
from low to high, Lower
the output drops - A +
very little.
Y B+
B+ Y B+ Y
B+
Low Low Low
- A + - A + - A +
Strong Interaction Moderate Reversal
High High
B- B-
Y Y
B+
B+ B+
Low Low
- A + - A +
4.5
Mean
3.5
2.5
(4.55 + 2.40)/2 = 3.48
1.5
When you select more than two variables MINITABTM generates an Interaction Plot
Matrix which allows you to look at interactions simultaneously. The plot at the upper
right shows the effects of Start Angle on Y at the two different levels of Fulcrum. The
red line shows the
effects of Fulcrum on
Y when Start Angle is
at its high level. The
black line represents
the effects of
Fulcrum on Y when
Start Angle is at its
low level.