DOE Simplified:: An Overview of Designed Experiments

Welcome to:
DOE Simplified:
An Overview of
Designed Experiments
By: Larry A. Scott
Principal: Process Technologies
Agenda
Intro to DOE:
Full Two-Level Factorials
Design: Eye-Hand Exercise
Analysis:
Interactions The Hidden Gold
Example: Engine Performance
Overall Strategy Of DOE
DOE Works on Any Process
DOE is:
Controllable Factors (X)
Process
A series of tests,
in which purposeful changes
are made to input factors,
Responses (Y)
so that you may identify causes

for significant changes
in the output responses.
Uncontrollable Variables (Z)
Design Terminology
OFAT vs. DOE (factorials)

Factor Effects
Main Effects
Interactions (effects)
Balanced Test Matrix
Array Codes
Prediction Equations (Y = mX + b)
Y = b0 + b1X1 + b2X2 + b12X1X2
Full TwoLevel Factorial Design
Run high/low combos of two or more factors

Use statistics to identify the critical few
Main effects
Interactions (the hidden gold!)
What could be simpler?
Exercise: Eye-Hand Coordination
Your mission: In a 10 second span, mark

as many dots in two circles as you can.
You must alternate between circles and
use only one hand.
2 inch
1 inch
Response: Number of dots in both circles.
Eye-Hand Coordination
Factors:
A. Which hand holds the pen:
Non-Dominant hand (ND)
+ Dominant (D)
B. Size of circle:
Small
+ Large
Factor Space and Test Matrix
Large
B
-
Small
ND
A
Hand
B
Size
AB
___
___
___
___
Templates
1. Small, Dominant: ___
2. Large, Dominant: ___
3. Small, Non-Dominant: ___

4. Large, Non-Dominant: ___
Procedure for Doing Exercise
1. Write the numbers 1 through 4 on four

slips of paper. Put these in one hand
and blindly pull out at random.
2. Following procedure in your notes,
perform tests in random run order.

Record data (Y) in blank at bottom of
templates. Chart on following graph.
Eye-Hand Exercise Outline
Reference:
DOE Simplified Practical Tools for Effective Experimentation
by Mark J. Anderson and Patrick J. Whitcomb, Productivity, Inc., Portland, OR
(2000).*
Interaction Graph
The Y-axis shows
the number of
dots (cycles).
Plot the data for
D vs. ND for the
small circles,
connect with a
line and label.
Then do same for
the large circles.
20
15
10
Non-Dominant
Dominant
Hand
Interaction Graph
Using statistical software, lets see how

well the Stat-Ease programming staff did
on this exercise and compare results.
Interaction Graph (published*)
Bullseyes
In this case, there

was a significant
interaction: the
effect of switching
hands became
more pronounced
with large circles.
"#
$%& '
B: Circle Size
45
40
35
30
Large
25
20
Small
15
Non-dominant
Dominant
A: Hand
+
,-.$
/ 00 $*
1$*2
$)
Real-World Example: OFAT Misses

Breakthrough Interaction!
130
B+
Life
90
50
B
10
A+
Factor Space and Test Matrix
Large
B
-
Small
ND
A
Hand
B
Size
AB
___
___
___
___
Relative Efficiency of Factorial vs

One Factor at a Time (OFAT)
(4
5 66666666666666
(4
5 66666666666666
(4
5 66666666666666
(4
566666666666666
(4
566666666666666
5 66666666666666
Advantages of DOE vs. OFAT

9 .
9 )
:.
9
9 2
9
,
8
9 .;
4
1
9 <
9
)
,
,
2
Relative Efficiency of Factorial vs.

One Factor at a Time (OFAT)
16
B+
128
85
26
19
21
C+
17
25
CA+
B-A-
Relative efficiency = 16/

16/8 = 2
Case Study: 23 Factorial Design

Background: An engineer wants to study the effect
of three factors on mileage performance of an engine.
'
Factor
Low ()
High (+)
Engine Speed (rpm)
2000
5000
Engine Torque (lb/ft)
52
Spark Angle (deg)
10
30
!
*
"
# $ $ %&
! (
23 Full Factorial Array

Std
Order
Y1
Y2
2000
10
4.5
13
5000
10
15.5
77
2000
32
10
9.8
201
5000
32
10
29.0
528
2000
30
3.7
27
5000
30
12.5
219
2000
32
30
9.1
324
5000
32
30
25.8
1010
Responses:
Y1 = fuel flow (lb/hr)
Y2 = NOx (g/hr)
Fuel Flow:
All Effects Calculated
Std
AB
AC
BC
ABC
Y1
4.5
15.5
9.8
29
3.7
12.5
9.1
Effect
9.38
-1.92
4.02
-1.18
+
+
25.8
-0.03 -2.13 13.73
Fill in effect of A. Which, if any, effects are significant?
Fuel Flow (Y1):

Calculating Effect of A (Engine Speed)
9.1
25.8
3.7
General formula:
12.5
+
9.8
Effect =
29
B
n+
Y
n
C
A
4.5
15.5
Engine speed
A effect =
Y+
15.5 + 29 + 12.5 + 25.8
4.5 + 9.8 + 3.7 + 9.1
= 13.4
Half-Normal Plot:
Identify the Big Effects
99
99
97
B
90
85
80
70
=
97
95
90
85
80
70
60
A
C
AB
B
AB
40
20
0
40
20
0
0.00
0.24
0.47
Effect
0.71
0.94
0.00
3.48
6.96
Effect
10.44
13.93
Sparsity of Effects Principle

Two types of effects:
Vital Few: the big ones we want to catch

20 % of ME'
s and 2FI'
s will be significant.
Trivial Many: the remainder that result from random variation.

These effects will be centered on zero.
Since they are based on averages,
you can assume normality
by the Central Limit Theorem*.
Half-Normal Probability Paper

92.86
78.57
Significant effects
(the vital few) fall
abnormally high (to
the right) on the
absolute effect
scale. These are
the keepers.
Pi
64.29
AB
50.00
35.71
21.43
7.14
0
|Effect|
12
15
What do you do with

the little ones?
Interactions The Hidden Gold

Fuel flow
The effect of speed

depends on the level
of torque. This is an
interaction.
Can you explain
whats happening to
the fuel flow?
30
24
gh
Hi
18
12
Lo
ee
Sp
d
pe e
s
w
6
0
B-
torque
B+
Analysis of Variance Report

(ANOVA)
!
*
+
0 00
= 0
= 3
2
>.
?.
>?
03
!3 =
)
+ @
!
0
0
=
" #$
%&
%%%'
New!
Minimum-Run Resolution IV Designs*

The minimum number of runs for
resolution IV design is only two times the
number of factors (runs = 2k). This can offer
quite a savings when compared to a regular
resolution IV 2k-p fraction.
! " #"
%&
%'(
)*+
Minimum-Run Resolution IV Designs

k
2k-p
Min
2k-p
Min
16
12
16
32
32*
16
14
17
64
34
16
16*
18
64
36
32
18
19
64
38
10
32
20
20
64
40
11
32
22
21
64
42
12
32
24
22
64
44
13
32
26
23
64
46
14
32
28
24
64
48
15
32
30
25
64
50
./
RSM: When to Apply It

Use factorial
design to get close
to the peak. Then
RSM to climb it.
Region of Interest
Region of Operability
RSM vs OFAT
Response
95
88
80
73
65
n
o
p
s
e
R
4
2
90
Factor B
85
0
-2
-4 -4
-2
90
4
75
Factor A
Response
Response
80
75
n
o
p
s
e
R
70
60
45
65
30
60
-2
-1
-2
-1
Factor A
Factor B
Advantages of DOE vs. OFAT

9 .
9 )
:.
9
9 2
9
,
8
9 .;
4
1
9 <
9
)
,
,
2

DOE Simplified:: An Overview of Designed Experiments

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DOE Simplified:: An Overview of Designed Experiments

Uploaded by

Copyright:

Available Formats

Welcome to:

DOE Works on Any Process

so that you may identify causes

Uncontrollable Variables (Z)

OFAT vs. DOE (factorials)

Full TwoLevel Factorial Design

Run high/low combos of two or more factors

What could be simpler?

Exercise: Eye-Hand Coordination

Your mission: In a 10 second span, mark

Response: Number of dots in both circles.

3. Small, Non-Dominant: ___

1. Write the numbers 1 through 4 on four

2. Following procedure in your notes,

perform tests in random run order.

Eye-Hand Exercise Outline

Using statistical software, lets see how

In this case, there

Real-World Example: OFAT Misses

Relative Efficiency of Factorial vs

Advantages of DOE vs. OFAT

Relative Efficiency of Factorial vs.

Relative efficiency = 16/

Case Study: 23 Factorial Design

Engine Speed (rpm)

Engine Torque (lb/ft)

Spark Angle (deg)

23 Full Factorial Array

Fill in effect of A. Which, if any, effects are significant?

Fuel Flow (Y1):

15.5 + 29 + 12.5 + 25.8

4.5 + 9.8 + 3.7 + 9.1

Sparsity of Effects Principle

Vital Few: the big ones we want to catch

Trivial Many: the remainder that result from random variation.

Half-Normal Probability Paper

What do you do with

Interactions The Hidden Gold

The effect of speed

Analysis of Variance Report

Minimum-Run Resolution IV Designs*

Minimum-Run Resolution IV Designs

RSM: When to Apply It

Advantages of DOE vs. OFAT

You might also like