DOE - iNTRO (wec)

DOE

INTRODUCTION

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Design of Experiments
•A systematic set of procedures and checks which permits one to
evaluate the effect of one or more factors without concern about
extraneous variables or subjective judgments.

•It begins with the statement of the experimental objective and ends
with the reporting of the results.

•It may often lead to further experimentation.

•It is the vehicle of the scientific method, giving unambiguous results

which can be used for inferring cause and effect.

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Objectives

After this section you will understand how to:

 Describe the overall concepts of 2K Factorials

 Design and Analyze a 23 Factorial using

 Anova
 Effects Plots
 Graphs and Residual Plots

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Strategy of Experimentation
The purpose of an experiment is
Define the Problem to better understand the real
world, not to understand the
Establish the Objective experimental data
Select the Output (Response) William Diamond
IBM - Retired Statistician
Select the Input Factors (KPIVs)
Choose the Factor Levels
Select the Experiment Design
Collect the Data
Analyze the Data
Draw Conclusions
Achieve the Objective
Design Of Experiments:
Any testing for which the inputs are controlled and
the analysis has been planned
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Strategy of Experimentation

Two Key Principles to consider:

•Replication : Re-running the entire experiment

•Randomization : Running the experiment trials

in such a way that there is not a pattern to the
order in which the trials are conducted

Replication & Randomization : The R&R of DOE

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Experimentation Sequence
Most often used to RSM Designs
study highly
To define the optimum operating window of
complicated effects
and relationships the key variables of high impact
involving two or
three variables. In
general, such designs
are employed to yield Full Factorial & 2K Designs
a reasonably precise
mathematical model To identify key variables of high impact
of the phenomenon
under investigation.

Fractional Factorial Designs

Most often limited to two levels and are
principally used for the study of Main Effects.

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Experimentation Sequence
RSM Designs
Used to study
To define the optimum operating window of
relatively
uncomplicated the key variables of high impact
effects and
interactions
resulting from a
relatively small
number of factors.
Full Factorial & 2K Designs
Generally speaking, To identify key variables of high impact
such designs are
based on the full
factorial model using
two or three levels.
Fractional Factorial Designs
Most often limited to two levels and are
principally used for the study of Main Effects.

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Experimentation Sequence
RSM Designs
To define the optimum operating window of
the key variables of high impact

Screening
experimentation is
used to determine Full Factorial & 2K Designs
which few factors
from a large host of To identify key variables of high impact
candidate factors
have the greatest
influence upon the
measured response.
These are usually Fractional Factorial Designs
done at the early Most often limited to two levels and are
stages of the
improvement process. principally used for the study of Main Effects.

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Advantages of 2K Factorials

 Good for early investigations - can look at a large

number of factors with relatively few runs

 Can be the basis for more complex designs

 Lends itself well to sequential studies

 Analysis is fairly easy

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2K Factorial Experiments
A 2k factorial is a designed experiment with k factors, each at
2 levels.
 Factors - one of the controlled or uncontrolled inputs into a
process whose influence upon a response is being studied
in the experiment
 Levels - the values at which you place the input factors

Example : 22 factorial

Factor Level 1 Level 2

Height 6 ft 9 ft
Weight 180 lb 230 lb

Note: This design requires 4 runs

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Standard Order of 2k Designs

The design matrix for 2K factorials is usually shown in standard
order. The low level of a factor is designated with a -1 and the
high level is designated with a 1. An example of a design
matrix for a 22 Factorial would look like this:

Temp Conc
-1 -1
1 -1
-1 1
1 1

Temp Conc Catalyst

-1 -1 -1
1 -1 -1
A 23 Factorial Looks like this : -1 1 -1
1 1 -1
-1 -1 1
1 -1 1
-1 1 1
1 1 1
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Exercise

 Create a 24 Factorial Design Matrix

 What are the minimum number of runs needed?

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a b c d
2x2 Design -1 -1 -1 -1
1 -1 -1 -1
-1 1 -1 -1
1 1 -1 -1
-1 -1 1 -1
2x2x2 1 -1 1 -1
Design
-1 1 1 -1
Answer
1 1 1 -1
-1 -1 -1 1
1 -1 -1 1
-1 1 -1 1
1 1 -1 1
2x2x2x2 -1 -1 1 1
Design 1 -1 1 1
-1 1 1 1
1 1 1 1

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Variables Data Example

Suppose you have been watching Golf on TV and are very interested in
all of the advertised items which claim to help generate improved
scores by increasing the distance you drive the golf ball. You are not
sure why these clubs & balls will improve distance, but you are anxious
for any improvement and purchase the following:
1) Two sets of Clubs a) Ping b) Callaway
2) Two Types of Golf Balls a) Titleist b) Pinnacle
You generally play at two courses and each has a differing wind
condition. Course A rarely has any wind as it is surronded by
mountains. Course B usually has high winds as it is located on the
prairie.
You’ve got the equipment.
You’ve checked the weather.
How do you know what to do to Improve your Game?
Let’s try a Designed Experiment . . .
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Strategy of Experimentation
Define the Problem:
My golf score is too high.

Establish the Objective:

Increase the distance I drive the golf ball down the
fairway.
Select the Response (Output) :
Distance, measured from the tee to the final
resting spot on the fairway, measured to
the nearest yard.

Distance (KPOV) is a Variables Type of Data

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Strategy of Experimentation

Select the Controllable Input Factors:

Golf Clubs
Golf Balls
Wind Condition

Identify the Uncontrollable Factors:

Temperature
Humidity
Grass Height
Golfer Fitness
Fatigue

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Strategy of Experimentation

Choose the Factor Levels :

Factors Level 1 Level 2

Clubs Ping Callaway
Golf Ball Titleist Pinnacle
Wind Condition Windy No Wind

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Strategy of Experimentation
Select the Experiment Design
How Do I Do the Experiment? What Do I Test?

Option 1 : OFAT - One Factor At a Time

A. Ping Clubs Type of Balls ??? Wind ???

B. Callaway Clubs Type of Balls ??? Wind ???

Drawbacks : Very limited information

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Strategy of Experimentation
Select the Experiment Design
How Do I Do the Experiment? What Do I Test?
Option 2 : Full Factorial
What Are All of the Possible combinations?
A. Ping Clubs Titleist Balls No Wind
B. Callaway Clubs Titleist Balls No Wind
C. Ping Clubs Pinnacle Balls No Wind
D. Callaway Clubs Pinnacle Balls No Wind
E. Ping Clubs Titleist Balls High Wind
F. Callaway Clubs Titleist Balls High Wind
G. Ping Clubs Pinnacle Balls High Wind
H. Callaway Clubs Pinnacle Balls High Wind
Let’s Look At It A Different Way
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Design of Experiment Structure

Ping Callaway No Wind

Clubs Clubs Titleist Ball
Callaway Clubs
Titleist A B
(yards) (yards)
No Wind
Pinnacle C D
(yards) (yards)

Titleist
E F High Wind
(yards) (yards)
Titleist Ball
High Wind
G H Ping Clubs
Pinnacle
(yards) (yards)

This is a Full Factorial Experiment.

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Design of Experiment Structure

Ping Callaway Distance

Clubs Clubs

Titleist A B
(yards) (yards)
No Wind
Pinnacle C D
(yards) (yards)

Titleist
E F
(yards) (yards)
High Wind
G H
Pinnacle
(yards) (yards)

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Strategy of Experimentation
Analyze the Data
Rules For Analyzing Variables Data
One Observation per Treatment More than One Observation per
Combination Treatment Combination
•Generate the Main Effects Plot & •Generate the Main Effects Plot &
Interactions Plot Interactions Plot
•Run the Anova Procedure •Run the Anova Procedure
(Stat>Anova>General Linear Model) (Stat>Anova>General Linear Model)
•CAN NOT analyze interactions •Test for Statistical Significance
•Test for Statistical Significance P< .05
P< .05 Starting with highest order interaction
•Run Diagnostics •Run Diagnostics
(Residuals & Fits) (Residuals & Fits)
•Loss of Information on Interactions •Able to statistically analyze interactions
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Strategy of Experimentation
Analyze the Data

Rules For Analyzing Attributes Data

•Main Effects Plot

(Stat>ANOVA>Main Effects Plot)
•Interactions Plot
(Stat>ANOVA>Interactions Plot)
•Run Binomial Analysis of Means
(Stat>ANOVA>Analysis of Means
•Binomial

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Strategy of Experimentation
Analyze the Data
Main Effects Plot :
•Graphs the change in the average response (KPOV) for a single
factor as it changes from one level to another

•Does the average response (KPOV) change when an input

factor (KPIV) goes from one level to another

•When plotted, a horizontal line indicates an input factor (KPIV)

is not an important factor Main Effects Plot - Means for Resistance

•The greater the slope, the more 96.7

important the input factor 95.9

Resistan 95.1

94.3

93.5
Factor is important
Temp Current

Factor is not important

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Strategy of Experimentation
Analyze the Data
Interactions :
•When the effect (KPOV) of varying the levels of one factor is
influenced by the level of another factor

•Do the combined levels of the input factors (KPIVs) change

the output (KPOV) over and above the singular effects of the
input factors
Interaction Plot - Means for Resistance

•When plotted, a difference in slope

Temp
-1
97.5 1

indicates an interaction is present 96.5

-1
1

95.5

Mean
•The greater the difference in slope, 94.5

the stronger the interaction 93.5

92.5

-1 1

•An OFAT (One Factor At a Time) Current

experiment misses interactions

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Example of a 23 Factorial

 This example relates two quantitative Input Factors (Temperature and

Concentration) and one qualitative Input Factor (Catalyst) to Viscosity.
 Problem : Twenty percent increase in customer complaints due to
reflectors falling off. A review of the data indicates a problem with
viscosity during the same timeframe
 Objective of Experiment : Determine the factors that influence
viscosity
 Select the Output (KPOV) : Viscosity
 Select the input factors and their levels :
The factors and levels:
 Temp : 160o C (-1) 180o C (1)
 Concentration (%) : 20 (-1) 40 (1)
 Catalyst : Brand A (-1) Brand B (1)

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Set up the Data Matrix

Full Factorial Experiment

Temp Conc Catalyst Your data matrix should

-1 -1 -1 look like this.
1 -1 -1
-1 1 -1
1 1 -1
-1 -1 1
1 -1 1
-1 1 1
1 1 1

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Another way of showing it...

Temp -1 Temp 1
Con -1 Con 1 Con -1 Con 1
Cat -1 60 54 72 68

Cat 1 52 45 83 80

This is a 2X2X2 full factorial design.

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Example of a 23 Factorial
How do I do this in Minitab ?
 The Design Matrix with results looks like:
Temp Conc Catalyst Viscosity
-1 -1 -1 60
1 -1 -1 72
-1 1 -1 54
1 1 -1 68
-1 -1 1 52
1 -1 1 83
-1 1 1 45
1 1 1 80

This is an example of a Full Factorial Experiment with only

one observation per Treatement Combination (Cell).

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Strategy of Experimentation
Analyze the Data
Rules For Analyzing Variables Data
One Observation per Treatment More than One Observation per
Combination Treatment Combination
•Generate the Main Effects Plot & •Generate the Main Effects Plot &
Interactions Plot Interactions Plot
•Run the Anova Procedure •Run the Anova Procedure
(Stat>Anova>General Linear Model) (Stat>Anova>General Linear Model)
•CAN NOT analyze interactions •Test for Statistical Significance
•Test for Statistical Significance P< .05
P< .05 Starting with highest order interaction
•Run Diagnostics •Run Diagnostics
(Residuals & Fits) (Residuals & Fits)
•Loss of Information on Interactions •Able to statistically analyze interactions
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1. Generate Main Effects and Interactions Plot

Main Effects Plot - Means for Viscosity

Stat>ANOVA>Main Effects 75

70

Viscosit
65

60

55

Temp Conc Catalyst

Main Effects Plot - Effect of Temperature appears to be important.

Interaction Plot - Means for Viscosity
1
1
1
1

Temp
Stat>ANOVA>Interaction Plot -1 -1

-1 -1

-1
-1
Conc 1
1

Cat

Interactions Plot - Temperature X Catalyst interaction appear important

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2. Run ANOVA
Stat>ANOVA>General Linear Model
General Linear Model
Factor Levels Values
Temp 2 -1 1
Conc 2 -1 1
Cat 2 -1 1

Analysis of Variance for Viscosit

Source DF Seq SS Adj SS Adj MS F P
Temp 1 1058.00 1058.00 1058.00 20.64 0.010
Conc 1 50.00 50.00 50.00 0.98 0.379
Cat 1 4.50 4.50 4.50 0.09 0.782
Error 4 205.00 205.00 51.25
Total 7 1317.50
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3. Run Diagnostics
Stat>ANOVA>Residuals Plot

Residual Model Diagnostics

Normal Plot of Residuals I Chart of Residuals
30
5 3.0SL=22.99
20
10
Residual

Residual
0 0 X=0.000

-10

-5 -20 -3.0SL=-22.99

-30
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 1 2 3 4 5 6 7 8
Normal Score Observation Number

Histogram of Residuals Residuals vs. Fits

2
5
Frequency

Residual
1 0

-5
0
-6 -4 -2 0 2 4 6 50 60 70 80
Residual Fit

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4. Test for Statistical Significance

Stat>ANOVA>General Linear Model
General Linear Model
Factor Levels Values
Temp 2 -1 1
Conc 2 -1 1
Cat 2 -1 1

Analysis of Variance for Viscosit

Source DF Seq SS Adj SS Adj MS F P
Temp 1 1058.00 1058.00 1058.00 20.64 0.010
Conc 1 50.00 50.00 50.00 0.98 0.379
Cat 1 4.50 4.50 4.50 0.09 0.782
Error 4 205.00 205.00 51.25
Total 7 1317.50

Temperature is statistically significant !!

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Reduced Model
We found that Temp and Temp*Catalyst were important, so use the
Anova procedure to run only those terms. This has the effect of
giving us multiple observations so we can perform a more
sophisticated analysis.
Run Anova>General Linear Model
Analyze only Temp and Temp*Catalyst Interaction can be analyzed
because you are running a
Select fits and residuals in Storage reduced model

Analysis of Variance for Viscosity

Statistically Significant
Source DF SS MS F P
Temp 1 1058.00 1058.00 76.95 0.001
Catalyst 1 4.50 4.50 0.33 0.598
Temp*Catalyst 1 200.00 200.00 14.55 0.019
Error 4 55.00 13.75
Total 7 1317.50

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Diagnostics
Residual Model Diagnostics
Look for a Normal Plot of Residuals I Chart of Residuals
4 10
straight line 3
3.0SL=8.169

2 Look for out

Residual

Residual
1
0 0 X=0.000 of control
-1
-2
conditions
-3 -3.0SL=-8.169
-4 -10
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5 1 2 3 4 5 6 7 8
Normal Score Observation Number

Histogram of Residuals Residuals vs. Fits

2 4
3
2
Frequency

Residual
1
1 0
-1
-2
-3
Look for a 0 -4
Look for
-3 -2 -1 0 1 2 3 4 50 60 70 80
symmetrical Residual Fit patterns
distribution

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Strategy of Experimentation
Analyze the Data
Rules For Analyzing Variables Data
•Run the Diagnostics (Residuals vs Fits)

Residual Model Diagnostics

Normal Plot of Residuals I Chart of Residuals

Look for a 30 3 .0 S L =2 7 .5 7
Look for out
10

straight line
20
of control
10
Residual

Residual
0 0 X =0 .0 0 0 conditions
-10
-20
-10
-3 .0 S L =-2 7 .5 7
-30
-2 -1 0 1 2 0 5 10 15
Normal Score Observ ation Number

Histogram of Residuals Residuals vs. Fits

5
10
4
Frequency

Look for a
Residual

3
0 Look for
normal, 2
patterns
1
symmetric -10
0
distribution -15 -10 -5 0 5 10 15 2990 3000 3010 3020 3030 3040
Residual Fit

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Conclusion

•Temperature and the interaction

between Temperature and
Catalyst are significant to
controling Viscosity

•The standard analysis and the

reduced model analysis indicated
the same results

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