Topic 5: Design of Experiments

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Design of Experiments

Experimentation
Approaches of Experimentation
Design of Experiment (DOE)
Experimental Design Process

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Experimental Analysis in Product
Realization

DEVELOPMENT

Research
Design
(properties, processes) (concepts, performance)

PRODUCTION

Validation QA
(processes, performance) (monitoring)

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Experimentation

The Blind Man and the Elephant

What we learn from an experiment may depend on

where we look, how we look, and the scope of our view!
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Experimentation

Experimenters first goal: Understand the

process!
Experiments - used to study effects of
parameters as they are set at various levels
Noise factors

Signal Measured
System
factors response

Control factors
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Control Factors

Control factors are factors whose values can

be selected and controlled by the engineer
Temperature, material type, current
At the end of an experiment
Control factor levels will be implemented
Therefore, they must be selectable

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Noise Factors

Noise factors cause the deviation of a functional

characteristic from the target value
There are 3 types of Noise factors
Outer (External) Noise
Variation in operating environment due to temperature,
humidity
Inner (Internal) Noise
Deterioration or wear of parts
Between product (Part-to-part) Noise
Manufacturing imperfection

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Signal Factors

Signal factors
Change the true mean of the quality characteristic
E.g. Height of throwing
Can be studied but the best level of a signal factor
cannot be chosen for optimum conditions
They are changed at point of use

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Experimental Design

Statistical process control (SPC) and experimental

design (DOE) powerful tools for the improvement
and optimization of processes.
SPC passive statistical method.
We watch the process and wait for some useful information.
DOE active statistical method.
We perform a series of tests by making changes in inputs
and observing corresponding changes in outputs.

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 Key Concepts
DOE is about better understanding of our processes
INPUTS OUTPUTS
(Factors) (Responses)
X variables Y variables

People

Materials

PROCESS: responses related

Equipment to performing a
service

responses related
Policies to producing a
A Blending of produce
Inputs which
Generates responses related
Procedures
Corresponding to completing a task
Outputs

Methods

Environment Illustration of a Process

 Steps in a Designed Experiments
Study

1. Brainstorm the problem / causes

2. Design the Experiment
3. Perform the experiment
4. Analyze the data
5. Validate your results
Cost of Experimentation

Resources (people, equipment, etc.)

Time
Material (unprocessed or unusable product)
Usable product that is not being produced

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Approaches to Experimentation

Build-test-fix
One-factor-at-a-time (the classical approach)
Designed experiments (DOE)

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Approaches to Experimentation: Build-Test-
Fix

Build--test-
Build test-fix
the tinkerers approach
pound it to fit, paint it to match
impossible to know if true optimum achieved
you quit when it works!
consistently slow
requires intuition, luck, rework
reoptimization and continual fire-fighting

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Approaches to Experimentation: One-
Factor-at-a-Time

One
One--factor-
factor-at
at--a-time
procedure (2 level example)
run all factors at one condition
repeat, changing condition of one factor
continuing to hold that factor at that condition, rerun with
another factor at its second condition
repeat until all factors at their optimum conditions
slow, expensive: many tests
can miss interactions!

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One-Factor-At-A-Time
Process: Yield = f(temperature, pressure)
50% yield
30%
yield

Max yield: 50% at 78C, 130 psi?

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One-Factor-At-A-Time
A better view of the maximum yield!
Optimized yield is over 85%

Process: Yield = f(temperature, pressure)

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Approaches to Experimentation: DOE

Design of Experiments (DOE)

A statistics-based approach to designed
experiments
A methodology to achieve a predictive knowledge
of a complex, multi-variable process with the
fewest trials possible
An optimization of the experimental process itself

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Major Approaches to DOE

Factorial Design
Taguchi Method
Response Surface Design

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DOE - Factorial Designs

Full factorial
simplest design to create, but extremely inefficient
each factor tested at each condition of the factor
number of tests, N: N = yx
where y = number of conditions, x = number of factors
example: 8 factors, 2 conditions each,
N = 28 = 256 tests
results analyzed with ANOVA
cost: resources, time, materials,

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DOE - Factorial Designs

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DOE - Factorial Designs - 23

Trial A B C
1 Lo Lo Lo
2 Lo Lo Hi
3 Lo Hi Lo
4 Lo Hi Hi
5 Hi Lo Lo
6 Hi Lo Hi
7 Hi Hi Lo
8 HiUEME 4393 Hi Hi 22
DOE - Factorial Designs

Fractional factorial
less than full
condition combinations are chosen to provide
sufficient information to determine the factor effect
more efficient, but risk missing interactions

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DOE Factorial Designs (Fractional: 7
factor, 2 level; 128 8)

Trial A B C D E F G
1 Lo Lo Lo Lo Lo Lo Lo
2 Lo Lo Lo Hi Hi Hi Hi
3 Lo Hi Hi Lo Lo Hi Hi
4 Lo Hi Hi Hi Hi Lo Lo
5 Hi Lo Hi Lo Hi Lo Hi
6 Hi Lo Hi Hi Lo Hi Lo
7 Hi Hi Lo Lo Hi Hi Lo
8 Hi Hi Lo Hi Lo Lo Hi 24
DOE - Taguchi Method

Taguchi designs created before desktop computers

were common
pre-created, cataloged designs intended to quickly find a set
of conditions that meet the criteria of success
previous slide an example of an L8 template
Designs cannot support response surface models
and are limited to only predicting at the points where
data was taken

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DOE - Response Surface: RSM

Goal: develop a model that describes a

continuous curve, or surface, that connects
the measured data taken at strategically
important places in the experimental window

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DOE - Response Surface: RSM

RSM uses a least-squares curve-fit

(regression analysis) to:
calculate a system model (what is the process?)
test its validity (does it fit?)
analyze the model (how does it behave?)

Bond = f(temperature, pressure, duration)

Y = a0 + a1T + a 2P + a3D
+ a11T2 + a22P2 + a33D2
+ a12TP + a13TD + a23PD

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Experimental Design Process

1. Determine the goals

2. Define the measures of success
3. Verify feasibility (rough estimate)
4. Design the experiment (precise estimate)
5. Run the experiment
6. Collect and analyze the data
7. Determine and verify the response
8. Act on the results

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Experimental Design Process

1. Determine the Goals

doing so often leads to:
goals are too many to cover in a single study
goals that seemed concrete are actually very negotiable
once consensus achieved, a valid experimentation
strategy can be developed
plan the action to be taken if the experiment is a success
or a failure

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Experimental Design Process

2. Define the measures of success

once the goals are set, how do we know when we are
meeting them?
measures must be metric and refer to an intrinsic feature
of the process or product
qualitative good/bad cannot be modeled
including a large number of responses just to see how
they change often diverts focus from the responses that
are critical to meeting the goals

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Experimental Design Process

2. Define the measures of success

Target Performance Measure
To see which factors affect mean
Objective measure to adjust to target
Noise Performance Measure
To see which factors affect variability
Objective measure to reduce variability

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Experimental Design Process

2. Define the measures of success

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Experimental Design Process

3. Verify feasibility (rough estimate)

use a power calculation to determine whether
any information can be found with a reasonable
number of trials
a function of the amount of noise associated with a
response
the more noise in the process, the more trials required
to see a change in the desired parameter

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Experimental Design Process

4. Design the experiment (precise estimate)

Identify the controls to be varied
Make the design
Determine whether the number of experiments
is too large
If necessary, use a screening design to sift through to
find the critical few

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Experimental Design Process

4. Design the experiment (precise estimate)

Cause-Effect Diagram (Fish-bone diagram)

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Experimental Design Process

5. Run the experiment

A task in resource management
Complete the work as efficiently and as
effectively as possible

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Experimental Design Process

5. Run the experiment

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Experimental Design Process

6. Collect and analyze the data

Best to examine the data as a whole
Analysis of a set of data has significant
advantage over contrasting the results between
two data points
Ability to find suspect data is greatly enhanced
If there is a choice as to order, you may wish to
obtain the most critical data first

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Experimental Design Process

6. Collect and analyze the data

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Experimental Design Process

7. Determine and verify the response

A Response Surface gives you the ability to
predict, with statistical limits, the behavior of the
process at any point within the design window
Combining predictions from several responses
allows you to simultaneously optimize for
several key specifications

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Experimental Design Process

7. Determine and verify the response

To Predict the TPM (or NPM)
PVTPM = y-bar + Main effects + Interaction effects
If interactions are negligible,
PVTPM = y-bar + Main effects
Conduct a confirmation experiment, CETPM
Is CETPM PVTPM?
Yes, the interaction effects 0 Experiment is repeatable.
No, the interaction effects 0 Return to the drawing
board.

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Experimental Design Process

8. Act on the results

Goals set earlier identified what was to be done
if success obtained do it!
If no action is taken, why was the experiment done?
Complete the documentation of the experiment

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Announcement
Mid-term Test

3rd JULY 2017 (MONDAY)

12pm -2pm

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Announcement

Submission of
Assignment
Submit
Before
12.00PM!!!

14th AUGUST 2017

(MONDAY)

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