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The Essentials of 2-Level Design of Experiments

This document provides an overview of full factorial designs. It discusses the motivation for using design of experiments (DOE) in industry, giving examples of how companies have benefited. DOE allows understanding how factors affect processes and determining optimal factor settings. Full factorial designs systematically vary all factors to determine their effects. The document outlines key concepts like factors, responses, and levels of understanding gained from experimentation.

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hyoung65
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57 views27 pages

The Essentials of 2-Level Design of Experiments

This document provides an overview of full factorial designs. It discusses the motivation for using design of experiments (DOE) in industry, giving examples of how companies have benefited. DOE allows understanding how factors affect processes and determining optimal factor settings. Full factorial designs systematically vary all factors to determine their effects. The document outlines key concepts like factors, responses, and levels of understanding gained from experimentation.

Uploaded by

hyoung65
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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The Essentials of 2-Level Design

of Experiments
Part I: The Essentials of Full Factorial
Designs

Developed by Don Edwards, John Grego and James Lynch


Center for Reliability and Quality Sciences
Department of Statistics
University of South Carolina
803-777-7800
Part I: The Essentials of Full
Factorial Designs
Some Motivation and Background
Two Important Advantages
of Factorial Experiments
The Essentials of 2-Cubed
Designs
Full Factorial Designs
I.1 Some Motivation
Arno Penzias
Chief Scientist and VP for Research, Bell
Labs & Nobel Laureate-Physics
Teaching Statistics to Engineers, Science Editorial, June 2
1989

Statistical Tools Are Needed In


Industry
Competitive Position Demands It
Optimizing Complex Technological
Manufacturing Processes Requires
It
I.1 Some Motivation

Leaders In Quality
Use Statistics At All Process Stages
For Quality and Optimization
Purposes
Provide The Necessary Statistical
Training To Do This
I.1 Some Motivation
QS9000
QS9000 required that

The supplier shall demonstrate


knowledge in Design of Experiments
(DOE) and use it as appropriate.
I.1 Some Motivation
Examples of DOE Applications
NCR has used factorial designs in a variety
of situations, e.g., to analyze computer
performance and to compare different
soldering methods.
Sara Lee Hosiery Division has used simple
designs in a number of settings. Several
have resulted in considerable annual
savings.
I.1 Some Motivation
Examples of DOE Applications
Ohio Brass has conducted several
fractional factorial designs which have had
significant impact. One study resulted in
an annual savings of $25K by modifying an
existing process and avoided a capital
investment of a 1/4 to 1/2 million dollars in
new equipment. Another enabled them to
reduce the dimensions of two key
components which resulted in annual
savings of $50K.
I.1 Some Motivation
Examples of DOE Applications

Michelin has used designs to determine


maintenance programs for some of their
machinery.
I.1 Background
Why Should You Use DOE?
Intelligent Decisions Should Be Based On
"Informed Observation And Directed
Experimentation" (George Box)
It is consistent with the Scientific Method
which is fundamental to the quality
management philosophy (The Deming-
Shewhart PDSA Cycle)
DOE is a formalism that forces you to
organize your thoughts (so you don't do
things haphazardly)
I.1 Background
Why Should You Use DOE?
DOE Concentrates Your Efforts
Screening designs aid in
identifying the vital/critical factors
that may affect the (process)
response of interest
More refined design techniques
determine the factor levels that
optimize the response
I.1 Background
Why Should You Use DOE?
DOE Concentrates Your Efforts
DOE helps you to understand how
factors affect the process. This
knowledge helps to choose factor
settings that are cost effective but
dont compromise quality
(constrained optimization).
I.1 Background
Quality Management Philosophy
Some Tenets Related to These
Components
All processes have variation
Different types of variation
e.g., common cause system verses special
causes being present
Management needs predictable/stable
processes to make decisions
(process needs to be in control, i.e., a
common cause variation system)
I.1 Background
Quality Management Philosophy
Implications for DOE
The smaller the effects you are trying
to detect relative to the background
variation, the more replication you
need or a different design (blocking)
Data from an out-of-control process is
suspect
I.1 Background
Contrasting SPC and DOE
Statistical Process Control (SPC)
SPC is used to determine if a
process is in control
An Out-of-Control process that is
brought into control is not process
improvement (Juran)
I.1 Background
Contrasting SPC and DOE
Design of Experiments (DOE)
A methodology useful for
determining
what factors may affect a response
what factor settings are feasible

SPCLets You Listen to the


Process;
DOE Allows You to Converse
With It
William Hunter
I.1 Background
Experimentation
Experiment
A series of trials or tests which produce
quantifiable outcomes.

Quantifiable Outcome
Some Outcome Measurement of Interest
Response Variable (y)
I.1 Background
Examples of Responses
Yield
Viscosity
Computer Performance
Breaking Strength of Fiber
Smoothness of Polyurethane Sheets
Bowing of a Molding
Chain Length in Polymer
Number of Flaws
I.1 Background
Responses- Bowing of a Molding
Three
Three Moldings
Moldings
Top
Top -- Most
Most
Severe
Severe Bowing
Bowing
Bottom
Bottom -- Flat,
Flat,
No
No Bowing
Bowing
I.1 Background
Responses- Bowing of a Molding
True versus Substitute Quality
Characteristics
The
The Displacement
Displacement D D
Substitute
Substitute Quality
Quality
Characteristic
Characteristic for
for
Bowing
Bowing
Measurable
Measurable
I.1 Background
Factors
Experimental(Variable) Conditions
That May Affect the Response.
A. Flow rate of a raw material
B. Process temperature
C. Presence/Absence of a Catalyst
D. Raw Material Supplier (e.g. 1,2, or 3)
I.1 Background
Factors
Factors May Be
Continuous (A and B Above)
Discrete (C and D Above)
I.1 Background
First Motivation To Experiment
ToImprove The Response.....
Optimize average response
Minimize variability in response
Minimize susceptibility to
uncontrollable noise factors
I.1 Background
Best Motivation
ToUnderstand The Response!
(George Box)
Levels of Understanding
Which?
How?
Why?
I.1 Background
Levels of Understanding
An Example - Yellowfin Tuna Growth
Traditional
Traditional
Theoretical
Theoretical Growth
Growth
Models Indian Ocean Yellowfin Tuna
Models Allow
Allow For
For Age versus Fork Length
Only
Only One
One Point
Point of
of 120

Inflection
Inflection 110
100
(Two Growth
(Two Growth 90

Stages)
Stages) Fork 80
Length 70
(cm) 60
50
40
30

0 500 1000
Age (days)
I.1 Background
Levels of Understanding : How
Stage
An Example - Yellowfin Tuna Growth
Lowess
Lowess Fit Fit
Suggests
Suggests Indian Ocean Yellowfin Tuna
Two
Two Points
Points of
of Age versus Fork Length
Inflection
Inflection
120
110
Rethink
Rethink Theory
Theory 100
90
Fork 80
Length 70
(cm)
60
50
40
30

0 500 1000
Age (days)
I.1 Background
Levels of Understanding: How Stage
An Example - Yellowfin Tuna Growth
More
More
Pronounced
Pronounced In In Atlantic Ocean Yellowfin Tuna
The
The Atlantic
Atlantic Age versus Fork Length
Ocean
Ocean 110

Yellowfin
Yellowfin Tuna
Tuna 100

90
Fork
Length 80
(cm)
70

60

50
400 500 600 700 800 900
Age (days)
Levels of Understanding: Why
Stage
An Example - Yellowfin Tuna
Growth
Atlantic Ocean Yellowfin Tuna
Age versus Fork Length
110
Gonadal
100 Stage

90
Fork
Length 80
(cm)
70
Somatic
60
Stages
50
400 500 600 700 800 900
Age (days)

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