4 Improve Designing Experiments v10 3

Improve Phase
Designing Experiments
M#
504
Welcome
Welcome to
to Improve
Improve
Process
Process Modeling:
Modeling:
Regression
Regression
Advanced
Advanced Process
Process Reasons
Reasons for
for
Modeling:
Modeling: MLR
MLR Experiments
Experiments
Designing
Experiments Graphical
Graphical Analysis
Analysis
Experimental DOE
DOE Methodology
Methodology
Experimental Methods
Methods
Full
Full Factorial
Factorial Experiments
Experiments
Fractional
Fractional Factorial
Factorial
Experiments
Experiments
Wrap
Wrap Up
Up &
& Action
Action Items
Items
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OSSS LSS Black Belt v10.3 - Improve Phase 2 505
© Open Source Six Sigma, LLC
Project Status Review
• Understand our problem and it’s impact on the

business. (Define)
• Established firm objectives/goals for improvement.
(Define)
• Quantified our output characteristic. (Define)
• Validated the measurement system for our output
characteristic. (Measure)
• Identified the process input variables in our process.
(Measure)
• Narrowed our input variables to the potential “X’s”
through Statistical Analysis. (Analyze)
• Selected the vital few X’s to optimize the output
response(s). (Improve)
• Quantified the relationship of the Y’s to the X’s with
Y=f(x). (Improve)
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Six Sigma Strategy
e rs C ts
Define p li us u
O
SIPOC
Sup tom Inp
ut
Con VOC
p
trac Emplo ers Project Scope
ut
tor s yees
Measure s
P-Map, X-Y,
(X1) (X2) (X3) (X4) (X8) (X11) (X9) FMEA
(X6) (X7) (X5) Capability
(X10)
Analyze (X4) (X1) (X11) Box Plot,

(X3)
(X8) Scatter
(X2) (X5) Plots,
Regression
(X5) (X3) Fractional

Improve (X11)
Factorial
Full Factorial
Center Points
(X4)
Business Success
Control Plan
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Reasons for Experiments
The Analyze Phase narrowed down the many inputs to a

critical few, now it is necessary to determine the proper
settings for the vital 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
–
sign where
X’s) you’re going - be sure you get there!
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Desired Results of Experiments
Problem Solving
– Eliminate defective products or services.
– Reduce cycle time of handling transactional processes.
Optimizing
– Produce a mathematical model 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.
When it rains it POURS! M#
DOE Models vs. Physical Models
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.
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Definition for Design of Experiments
Design of Experiments (DOE) is a scientific method of

planning and conducting an experiment that will
yield the true cause and effect relationship between
the critical X variables and the Y variables 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).
The end result of many experiments is to describe
the results as a mathematical function.
Y = f (x)
The goal of DOE is to find a design that will produce
the information required at a minimum cost.
Properly designed DOE’s are more efficient experiments

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One Factor at a Time is NOT a DOE
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.
Trial Pressure Temp Yield
Yield Contours Are 1 125 30 74
Unknown To Experimenter 75 2 125 31 80
3 125 32 85
4 125 33 92
80 5 125 34 86
6 130 33 85
Pressure (psi)
7 120 33 90
135 85
6
130 90
125
1 2 3 4 5 Optimum identified
95 with OFAT
120
7
True Optimum available

30 31 32 33 34 35 with DOE
Temperature (C)
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Types of Experimental Designs
The most common types of DOE’s are:

– Fractional Factorials (aka Screening
DOEs)
• 4-15 input variables
– Full Factorials
• General Full Factorials
• 2k Full Factorials
• 2-5 input variables
– Response Surface Methods (RSM)Response
• 2-3 input variables Surface
Full Factorial
KNOWLEDGE
Fractional Factorials
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Nomenclature for Factorial Experiments
The general notation used to designate a 2-level full

factorial design is given by:
– 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.
This is a 24 example (4 factors at 2 levels)
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Visualization of 2 Level Full Factorial
600 (-1,+1) (+1,+1)

300
Temp
350
2 2
Press
500
Press
600 500
Uncoded levels for factors (-1,-1) (+1,-1)
300F Temp 350F
T P T*P
-1 -1 +1 Four experimental runs:
+1 -1 -1 • Temp = 300, Press = 500
-1 +1 -1 • Temp = 350, Press = 500
+1 +1 +1 • Temp = 300, Press = 600
Coded levels for factors • Temp = 350, Press = 600
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Graphical DOE Analysis - The Cube Plot
Consider a 23 design on a
catapult...
8.2 4.55 A B C Response
Run Start Stop Meters

Number Angle Angle Fulcrum Traveled
3.35 1.5 1 -1 -1 -1 2.10
2 1 -1 -1 0.90
Stop Angle
3 -1 1 -1 3.35
5.15 2.4 4 1 1 -1 1.50
5 -1 -1 1 5.15
6 1 -1 1 2.40
Fulcrum
7 -1 1 1 8.20
2.1 Start Angle 0.9 8 1 1 1 4.55
What are the inputs being manipulated in this design?

How many runs are there in this experiment?
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Graphical DOE Analysis - The Cube Plot
Open the MINITABTM worksheet “Catapult.mtw”

Stat > DOE > Factorial > Factorial Plots…
check Cube Plot box and click Setup…
select response and factors
Cube Plot (data means) for Distance
8.20 4.55
3.35 1.50
This graph is used by 1
the experimenter to
visualize how the What
response data is are Stop Angle 5.15 2.40
distributed across the
these 1
experimental space.
How do you read or ? 2.10 0.90
Fulcrum
interpret this plot? -1

-1 1
-1
Start Angle
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Graphical DOE Analysis - The Main Effects Plot
check “Main Effects Plot” box and click “Setup…”
to select response and factors
Main Effects Plot for Distance

Data Means
This graph is used to see Start Angle Stop Angle
the relative effect of each 5
factor on the output 4
response. 3
Which factor’s 2
Mean
-1 1 -1 1
main effect has 5
Fulcrum
the largest 4
impact on the 3
output? 2
Hint: Check the -1 1

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511
slope!
OSSS LSS Black Belt v10.3 - Improve Phase 15 © Open Source Six Sigma, LLC
Main Effects Plots’ Creation
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
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Interaction Definition
Interactions occur when variables act together to impact

the output of the process. Interaction plots are constructed
by plotting both variables together on the same graph. They
take the form of the graph below. Note that in this graph, the
relationship between variable “A” and output Y changes as the
level of variable “B” changes. When “B” is at its high (+)
level, variable “A” has almost no effect on Y. When “B” is at its
low (-) level, A has a strong effect on Y. The feature of
interactions is non-parallelism between the two lines.
High
B- When B
changes from
Y low to high,
When B
Output
with A at high,
changes from the output
low to high, changes
with A at low, dramatically.
the output
B+
Low
changes very
little. A- A+
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Degrees of Interaction Effect
Some Interaction No Interaction Full Reversal

High High High
B- B-
B-
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 +
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Interaction Plot Creation
Interaction Plot (data means) for Distance

Start Angle
6.5
-1
1
5.5
4.5
Mean
3.5
2.5
(4.55 + 2.40)/2 = 3.48
1.5
(0.90 + 1.50)/2 = 1.20 -1 1

Fulcrum
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
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Graphical DOE Analysis - The Interaction Plots

Check “Interaction Plot” box and click “Setup…”
to input response and factors
Interaction Plot for Distance

When you select more than two Data Means
variables, MINITABTM generates an -1 1 -1 1
Interaction Plot which allows you to 6

Start
Angle
look at all factor interactions 4
-1
Star t A ngle 1
simultaneously. The plot at the
2
upper right shows the effects of Start
Angle on Y at the two different 6
Stop
Angle
levels of Fulcrum. The red 4
-1
Stop A ngle 1
dashed line shows the effects of
Fulcrum on Y when Start Angle 2
is at its high level. The black

solid line represents the effects
of Fulcrum on Y when Start Fulcr um
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Angle
OSSS LSSis atBelt
Black itsv10.3
low level.
- Improve Phase 20 514
Graphical DOE Analysis - The Interaction Plots

Check “Interaction Plot” box, click “Setup..” button, then click “Options...” button
Check this option for

these additional
plots
Interaction Plot for Distance
The plots at the lower Data Means
left in the graph below 6

-1 1
Start
(outlined in blue) are the 4

A ngle
-1
Star t A ngle 1
“mirror image” plots of 2
those in the upper right. 6

Stop
A ngle
It is often useful to look Stop A ngle
4
-1
1
at each interaction in 2
both representations. 6
Fulcrum
-1
1
4
Fulcr um
-1 1 -1 1 M#
DOE Methodology
1. Define the Practical Problem

2. Establish the Experimental Objective
3. Select the Output (response) Variable
4. Select the Input (independent) Variables
5. Choose the Levels for the Input Variables
6. Select the Experimental Design
7. Execute the experiment and Collect Data
8. Analyze the data from the designed experiment
and draw Statistical Conclusions
9. Draw Practical Solutions
10.Validate the experimental results
11.Implement Solutions
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Generate 2-level Full Factorial Designs in MINITABTM
Stat > DOE > Factorial > Create Factorial Design…

A 23 Full Factorial
design will result in 8
experimental runs.
Full Factorial
Experimental Designs
are always Green!
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Create Three Factor 2-level Full Factorial Design
Stat > DOE > Factorial > Create Factorial Design…
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Three Factor 2-level Full Factorial Design
Hold on! Here we go….

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OSSS LSS Black Belt v10.3 - Improve Phase © Open Source Six Sigma, LLC
Summary
At this point, you should be able to:
• Determine the reason for experimenting
• Describe the difference between a physical model and a

DOE model
• Explain an OFAT experiment and its primary weakness
• When shown a Main Effects Plot and Interaction Plot,

determine which effects and interactions may be
significant.
• Create a Full Factorial Design

M#
28 518
OSSS LSS Black Belt v10.3 - Improve Phase © Open Source Six Sigma, LLC

4 Improve Designing Experiments v10 3

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Improve Phase

• Understand our problem and it’s impact on the

Analyze (X4) (X1) (X11) Box Plot,

(X5) (X3) Fractional

The Analyze Phase narrowed down the many inputs to a

What are the differences between DOE modeling and

Design of Experiments (DOE) is a scientific method of

Properly designed DOE’s are more efficient experiments

One Factor at a Time (OFAT) is an experimental style but

True Optimum available

The most common types of DOE’s are:

The general notation used to designate a 2-level full

– Where k is the number of input variables or

This is a 24 example (4 factors at 2 levels)

600 (-1,+1) (+1,+1)

300F Temp 350F

8.2 4.55 A B C Response

Run Start Stop Meters

What are the inputs being manipulated in this design?

Open the MINITABTM worksheet “Catapult.mtw”

Cube Plot (data means) for Distance

interpret this plot? -1

Main Effects Plot for Distance

factor on the output 4

Hint: Check the -1 1

Interactions occur when variables act together to impact

Some Interaction No Interaction Full Reversal

Interaction Plot (data means) for Distance

(0.90 + 1.50)/2 = 1.20 -1 1

Run # Start Angle Stop Angle Fulcrum Distance

Stat > DOE > Factorial > Factorial Plots…

Interaction Plot for Distance

variables, MINITABTM generates an -1 1 -1 1

Interaction Plot which allows you to 6

is at its high level. The black

Stat > DOE > Factorial > Factorial Plots…

Check this option for

left in the graph below 6

(outlined in blue) are the 4

those in the upper right. 6

1. Define the Practical Problem

Stat > DOE > Factorial > Create Factorial Design…

Stat > DOE > Factorial > Create Factorial Design…

Hold on! Here we go….

At this point, you should be able to:

• Determine the reason for experimenting

• Describe the difference between a physical model and a

• Explain an OFAT experiment and its primary weakness

• When shown a Main Effects Plot and Interaction Plot,

• Create a Full Factorial Design

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