Introduction to Design
Experiments
Vianney Andrew Yiga
[Link]@[Link]
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Research cycle
Ask Question:
Objective of study
Analyze the result
to answer the Data Collection
question
Experimental
Graphical analysis
Design
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Experimental Design
• Conventional method • Statistical method
-One factor at a time (OFAT) -Known as Design of Experiment (DOE)
-Time consuming -Apply factorial concept
-Cannot interpret the interaction -Use the modelling to predict the
between 2 or more variables behavior of process variables
-RSM, ANN etc.
-Could explain the interaction between
the process variables
-Reduce lead time and improve
efficiency
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What isDOE?
DoE is a method of experimenting with complex
processes with the objective of optimizing the process.
What isRSM?
Response Surface Methodology is a set of statistical
techniques employed on a regression analysis to factors
for optimizing response behaviors.
What isDesign Expert, MiniTab and etc?
• tools to help us design our experiments and
analyze our data.
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Design of experiments seeks to:
• Determine which variables affect the system.
• Determine how the magnitude of the variables affects the system.
• Determine the optimum levels for the variables.
• Determine how to manipulate the variables to control the response.
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What can RSM do?
• Prediction • Optimization
-Could predict the -Could find the values of the factors
relationship/interaction between the that produces the best value or values
values of some measureable response of the response(s).
variable(s) and those of a set of
experimental factors presumed to
affect the response(s)
-Predict the response value at various
process condition
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Flow of RSM
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Methods of Experimentation
• Trial and Error
• Single Factor Experiment
one change at a time
• Fractional Factorial Experiment
change two or more things at a time
• Full Factorial Experiment
change many things at a time
• Others (Box-Jenkins, Taguchi, etc.)
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Trial and Error experiments
• Lack direction and focus
• Guesswork
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Single Factor Experiment
– A single factor experiment allows for the manipulation of
only one factor during an experiment.
• Select one factor and vary it, while holding all other factors constant.
– The objective in a single factor experiment is to isolate the
changes in the response variable as they relate to the single
factor.
– These types of experiments are:
• Simple to Analyze
– Only one thing changes at a time and you can see what affect that change has on
the system.
• Time Consuming
– Changing only one thing at a time can result in dozens of repeated experiments.
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Single Factor Experiment
– In these types of experiments:
• Interactions between factors are not detectable.
– These experiments rarely arrive at an optimum setup because a
change in one factor frequently requires adjustments to one or
more of the other factors to achieve the best results.
– Life isn’t this simple
• Single factor changes rarely occur that are not inter-
related to other factors in real life.(reason why we need to lean Design Expert software)
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Fractional Factorial Experiment
– Studies only a fraction or subset of all the possible
combinations.
• A selected and controlled multiple number of factors are adjusted
simultaneously.
– This reduces the total number of experiments.
– This reveals complex interactions between the factors.
– This will reveal which factors are more important than others.
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Full Factorial Experiment
– A full-factorial design consists of all possible combinations of
all selected levels of the factors to be investigated.
• Examines every possible combination of factors at all levels.
– A full-factorial design allows the most complete
analysis
• Can determine main effects of the factors manipulated on response
variables
• Can determine effects of factor interactions on response variables
• Can estimate levels at which to set factors for best results
– Time consuming 13
ANOVA
• An ANOVA is an Analysis of Variance
– Used to determine whether or not changes in factor
levels have produced significant effects upon a response
variable.
• An ANOVA estimates the variance of the X using two- three
different methods.
– If the estimates are similar, then detectable differences between the subgroup
averages are unlikely.
– If the differences are large, then there is a difference between the subgroup
averages that are not attributable to background noise alone.
– ANOVA compares the between-subgroup estimate of variance of x with the
within subgroup estimate.
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Definitions
– Factor:
• The variable that is changed and results observed.
• A variable which the experimenter will vary in order to determine its effect on a
response variable.
• » (Time, temperature, pressure, filler content, …)
– Level:
• A value assigned to change the factor (low, center, high).
• » Temperature; Level 1: 100, Level 2: 200
– Effect:
• The change in a response produced by a change in the factor level.
– Degree of Freedom:
• The number of levels of a factor minus 1.
– Interaction:
• Two or more factors that, together, produce a result different than what the
result of their separate effects would be. 15
Definitions
– Noise factor:
• An uncontrollable (but measurable) source of variation in the functional
characteristics of a product or process.
– Response variable/ Responses:
• The variable(s) used to describe the reaction of a process to variations in control
variables (factors).
• The Quality characteristic under study, e.g. Tensile strength (Yiga et al., 2021).
– Treatment:
• A set of conditions for an experiment
– factor x level used for a particular run.
– Run:
• An experimental trial. The application of one treatment to one experimental unit.
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Characteristics of a Good Experiment Design
– The experiment should provide unbiased estimates of process variable
and treatment effects (factors at different levels).
– The experiment should provide the precision necessary to
enable the experimenter to detect important differences.
– The experiment should plan for the analysis of the results.
– The experiment should generate results that are free from ambiguity of
interpretation.
– The experiment should point the experimenter in the direction of
improvement.
– The experiment should be as simple as possible.
• Easy to set up and carry out
• Simple to analyze and interpret
• Simple to communicate or explain to others
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Processes, factors and responses
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Processes, factors and responses- Example
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Daily life experiments
• Photography
– Factors: speed of film, lighting, shutter speed
– Response: quality of photographs
• Boiling water
– Factors: Pan type, burner size, cover, fuel calorific value
– Response: Time to boil water
• Mailing
– Factors: stamp, area code, time of day when letter is mailed
– Response: Number of days required for letter to be delivered
• Cooking chicken
– Factors: amount of cooking fuel, fuel calorific value, amount of tomatoes, time to cook
– Response: Taste of chicken
• Basketball
– Factors: Distance from basket, type of shot, location on floor
– Response: Number of shots made (out of 10) with basketball
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After DoE
• Complete data
-Insert the collected data into the software
• Develop the model
-First Order polynomial or Second Order polynomial
• Statistic analysis of model
-Regression analysis and ANOVA (R, R-sqaured, F value)
• Importance/significant of process variables
-T-value and p-value, Pareto chart, Probability plot
• Interaction/influence of process variables
-Contour plot, Surface (3D), Single parameter
• Optimization
-Single response, Multi response
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