Chapter 6

The 2k Factorial Design

The 2K Factorial Design:
• A special case of the factorial designs, with
each factor at two levels.
• Factor levels may be qualitative or
quantitative (-1, +1).
• Suited for screening experiments.
• Each complete replicate of such design
requires a total of (2).(2).(2)….(k)= 2 k runs.
Assumptions:
• Independent Factors
• Completely Randomize Order
• Experimental Errors are NID (0, 2)
The 22 Design
Consider an experiment involving two
factors A and B. Each at two levels:
low (-), and high (+)

If the experiment is replicated n times, then

the total number of runs (experimental
units) required is:
N = a.b.n = 4n
Notation: lower case letters represent
treatment totals at the high level of the
factor. (1) is used when both at the low
level.

+ b ab

- (1) a

- A +
Yates’ Standard Order:
1. Arrange the factors in convenient order.
2. Code the levels of each factor.
3. Arrange factor levels in a table such that
column k starts with 2K-1 (-1) values
followed by equal number of (+1) values.
3. Obtain the two factor interaction
column by multiplying the entries of
corresponding rows.
4. List treatment combination totals in
the last column.
The Design Matrix
(Yates’ standard order)

Run A B AB Totals
1 - - + (1)
2 + - - a
3 - + - b
4 + + + ab
Contrasts:
Simply multiply column entries by
corresponding total and add to obtain;

Contrast A  [(1)  a  b  ab]

Contrast B  [(1)  a  b  ab]
Contrast AB  [(1)  a  b  ab]
The Sum of Squares
1
SS x  (Contrast x ) 2

4n

Factor Effect
1
Effect x  (Contrast x )
2n
The Sum of Squares

1
SS A  [1  a  b  ab] 2

4n
1
SS B  [1  a  b  ab]2
4n
1
SS AB  [1  a  b  ab]2
4n
2 2 n 2
y...
SSTotal   yijk  2

i 1 j 1 k 1 4n
SS Error  SSTotal  SS A  SS B  SS AB
The ANOVA Table:

Source SS df MS F0
A SSA 1
MSA
B SSB 1 MSB
AB SSAB 1 MSAB
Error SSError 4(n-1) MSError
Total SSTotal 4n-1
Main Effects
1
A  [1  a  b  ab]
2n
1
B  [1  a  b  ab]
2n
Interaction
1
AB  [1  a  b  ab]
2n
Example
An engineer is interested in the effect of the
concentration of the reactant and the amount
of catalyst on the yield in a chemical process.
The reactant concentration (A) is tested at
two levels (15 and 25%), and the amount of
catalyst (B) at the two levels (1 and 2
pounds). The experiment is replicated three
times and the results are:
 Factors Replicate
Run A B AB I II III Totals
1 - - + 28 25 27 80
2 + - - 36 32 32 100
3 - + - 18 19 23 60
4 + + + 31 30 29 90
The ANOVA Table:
Source SS df MS F0 P-value

A 208.33 1 208.33 53.15 0.0001

B 75.00 1 75.00 19.13 0.0024

AB 8.33 1 8.33 2.13 0.1826
Error 31.34 8 3.92
Total 323.00 11
Model Adequacy:
The residuals are given by the difference
between observed response and the fitted
value (reduced model);

eijk  y ijk  yˆ ijk

Where,
yˆ ijk  ˆ  ˆi  ˆ j
Or, using the regression model ;
yˆ ijk  ˆ0  ˆ1 x1  ˆ2 x2
A B
 ˆ  ( ) x1  ( ) x2
2 2
Where,
x1 and x2 are variables representing (-1, +1)
coded levels of each factor;
A and B are their total effects.
e1 = 2.165, e2 = -0.835, e3 = 1.165
e4 = 1.835, e5 = -2.165, e6 = -2.166
e7 = -2.835, e8 = -1.835, e9 = 2.165
e10 = 1.835, e11 = 0.835, e12 = -0.165
Normal Plot of Residuals

99
Normal % Probability

95
90
80
70
50
30
20
10
5

-2.833 -1.583 -0.3333 0.9167 2.167

Residual
 Residuals vs. Predicted
3

1.5
Residuals

-1.5
2

-3
20.83 24.17 27.50 30.83 34.17

Predicted Yield ŷijk

 3 Residuals vs. A
2
2
1.5
Residuals

-1.5
2

-3

-1 0 1
Concentration (A)
 3 Residuals vs. B

1.5
Residuals

-1.5
2

-3

-1 0 1
Catalyst (B)
 Main Effects Plot for Yield
33

31
Yield

29

27

25

23
-1.0 1.0 -1.0 1.0

Concentration Catalyst
REGRESSION MODEL
 8.33 conc  20  5.00 Catalyst  1.5
y  27.5  ( )( )( )( )
2 5 2 0.5

 8.33  5.00
y  27.5  ( )( x1 )  ( )( x2 )
2 2
Response Surface
34.1667
30.8333
Yield 27.5
24.1667
20.8333

1.00
0.50 1.00
0.50
0.00 0.00
B: B -0.50 -0.50
A: A
-1.00 -1.00
 1.00 3
Yield 3
Contour Plot

23.06
0.50

25.28

B: B
0.00 27.50
29.72

-0.50 31.94

-1.003 3
-1.00 -0.50 0.00 0.50 1.00

A: A
The 23 Design (8 runs per replicate)

Run A B C AB AC BC ABC Totals

1 - - - + + + - (1)
2 + - - - - + + a
3 - + - - + - + b
4 + + - + - - - ab
5 - - + + - - + c
6 + - + - + - - ac
7 - + + - - + - bc
8 + + + + + + + abc
The ANOVA Table:
Source SS df MS F0
A SSA 1 MSA
B SSB 1 MSB
C SSC 1 MSC
AB SSAB 1 MSAB
AC SSAC 1
BC SSBC 1
ABC SSABC 1
Error SSError 8 (n-1)
Total SSTotal 8n-1
 Example
A study is conducted to determine the effect
of three variables on a filling process. The
percent carbonation (A), operating pressure
(B), and line speed (C) all are tested at two
levels.
The ANOVA Table:

Source SS DF MS F Prob > F

Model 73.00 7 10.43 16.69 0.0003
A 36.00 1 36.00 57.60 < 0.0001
B 20.25 1 20.25 32.40 0.0005
C 12.25 1 12.25 19.60 0.0022
AB 2.25 1 2.25 3.60 0.0943
AC 0.25 1 0.25 0.40 0.5447
BC 1.00 1 1.00 1.60 0.2415
ABC 1.00 1 1.00 1.60 0.2415
Pure Error 5.00 8 0.63
Cor Total 78.00 15
 The ANOVA Table (Reduced Model):

Source SS DF MS F Prob > F

Model 70.75 4 17.69 26.84 < 0.0001
A 36.00 1 36.00 54.62 < 0.0001
B 20.25 1 20.25 30.72 0.0002
C 12.25 1 12.25 18.59 0.0012
AB 2.25 1 2.25 3.41 0.0917
Residual 7.25 11 0.66
Lack of Fit 2.25 3 0.75 1.20 0.3700
Pure Error 5.00 8 0.63
Cor Total 78.00 15
The Response Surface
C: C = 0.00
4
Fill Deviation 2.6875
1.375
0.0625
-1.25

1.00
0.50 1.00
0.50
0.00
0.00

Pressure (B) -0.50 -0.50

Carbonation (A)
-1.00 -1.00
 Fill Deviation
Contour Plot 1.00

3.125
C: C = 0.00
0.50 2.25
Pressure (B)

1.375
0.00 0.5

-0.375

-0.50

-1.00
-1.00 -0.50 0.00 0.50 1.00

Carbonation (A)
AN EXAMPLE OF A 23 FACTORIAL
DESIGN

A = gap, B = Flow, C = Power, y = Etch Rate

Table of – and + Signs for the 23 Factorial Design
ESTIMATION OF FACTOR
EFFECTS
ANOVA SUMMARY – FULL
MODEL
REFINE MODEL – REMOVE NONSIGNIFICANT
FACTORS
 MODEL SUMMARY STATISTICS FOR REDUCED
MODEL

 R2

SS 5.106  10 5
R 2  Model   0.9608
SST 5.314 10 5

SS E / df E 20857.75 /12
R 2
Adj  1  1  0.9509
SST / dfT 5.314 10 /15
5