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Pat Hammett
Uncontrollable Variables - environmental factors those that are difficult or very expensive to control. (e.g., ambient temperature)
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Design of Experiments
Pat Hammett
Signal Noise Duality Factors location & Factors (dispersion effects) dispersion (location effects)
Dispersion Effect?
Yes No Yes Duality Factor Adjustment Factor No Noise Factor Robust Factor
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Location Effect?
Operating Windows
Defined:
Output Variable
Input Variable
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Design of Experiments
Pat Hammett
Summary of Terminology
n
Most input variables have a robust operating window in which the output is insensitive or able to meet manufacturing specifications. (i.e., relatively few pure linear relationships).
Output Variable
Input Variable
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Identify key input variables which affect the mean or variation of a key product output variable. After determining key inputs, mfgs should either:
n n n
Identify robust levels and establish controls to maintain, Fix the settings for an input variable, or Remove input variable effect by re-designing process.
If an input variable does not affect the output, then a mfg may either:
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Ignore the variable. Establish control plan to insure that input continues to have no impact on output.
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Design of Experiments
Pat Hammett
Conducting an Experiment
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Identify the process output(s) of concern. Identify process input variables which you believe affect the process output. Select input variables to study.
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Select levels or settings for each process input variable. Run the experiment at various combinations of levels. Analyze the data for significant main effects (input variable effects) and interaction effects.
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F - fix the settings for input variable I - ignore the settings for an input variables R - randomize the settings for an input variable M - model the variable - identify settings for your variables in which you want to test.
Remember the cost of experimentation can grow significantly if too many variables and/or levels of variables are selected.
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Design of Experiments
Pat Hammett
Experimental Combinations
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number of factors (input variables), number of levels for each factor, number of factor interactions you wish to study.
Suppose you wish to study three variables (factors) with two levels for each variable.
Experimental Combinations = LF = 23 = 8 combinations (Full Factorial Design) L = # of Levels, F= # of Factors
How many total combinations would you have if you tested 2 factors at 2 levels and 1 factor at 3 levels?
Input Variables
Model (FIRM)
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Design of Experiments
Pat Hammett
Fill Rate
1.0 1.3 1.2 1.4 2.8 3.2 3.5 3.3
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Short
Tall
Design of Experiments
Pat Hammett
Length of Chute
Which factor(s) are location effects? How might you determine if a factor is an adjustment factor?
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To test for significance of variables: Use Regression Function (Under Data Analysis of the Tools Menu) See above for input range in regression function.
Note: You can only use the regression function in excel for DOE if you only have two levels for each factor.
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Design of Experiments
Pat Hammett
Note: the larger the R2, the more you explain the Variation in your output.
Coefficients Standard Error 2.2125 0.064951905 0.1375 0.064951905 0.9875 0.064951905 0.0875 0.064951905
Factor interactions?
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Simultaneous effect of two or more factors on the response variable. Two-way interactions (involve two variables)
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Box-Filling Example: Chute Diameter x Chute Length Note: beyond the scope of this class.
Length = tall
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3.5
Length = medium
small
Chute Diameter
Design of Experiments
Pat Hammett
LengthxSize 1 -1 1 -1 -1 1 -1 1
DiameterxSize 1 -1 -1 1 1 -1 -1 1
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small
Chute Diameter
large
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Design of Experiments
Pat Hammett
Catapult Example
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The table below represents raw data from an experimental design on the catapult. Factors = return height (3 levels: low,medium,high) & ball position (2 levels: position 1 and position 2) Output Variable is launch distance (n=4 samples / comb.)
A 1 2 3 4 5 6 7 8 9 Pos 1 B Low 71 75 77 76 51 53 48 50 C Medium 74 71 69 74 50 52 46 48 D High 67 69 66 68 45 41 40 42
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Pos 2
Note: you may have to use add-in function for tool pack. Two-Factor ANOVA inputs for this example: n input range: A1:D9, rows per sample: 4 alpha: 0.05
A 1 2 3 4 5 6 7 8 9 Pos 1 B Low 71 75 77 76 51 53 48 50 C Medium 74 71 69 74 50 52 46 48 D High 67 69 66 68 45 41 40 42
Pos 2
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Design of Experiments
Pat Hammett
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Note: the sample variable is the row variable. In this case, ball position.
ANOVA Source of Variation Position Sample Height Columns Interaction Within Total
df
MS F P-value F crit 1 3528.375 699.843 7E-16 4.414 2 132.7917 26.33884 5E-06 3.555 2 3.125 0.619835 0.5491 3.555 18 5.041667 23
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Design of Experiments
Pat Hammett
Suppose your objective is to hit a target 50 away with a tolerance of +/- 8. What level(s) for each input variables would you need to produce less than 3.4 DPM?
n
Note: try to make your process as robust as possible to your input variables.
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55 50 45 40 35
Low
Medium
Return Height
High
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Design of Experiments
Pat Hammett
How might you improve this process to meet your six sigma quality objectives? Should you rely on the variance from your experiment to determine if you are able to achieve your six sigma quality objectives?
Low 51 53 48 50 Medium 50 52 46 48 =ftest() =ttest() Average StDev Pp Ppk 0.73 0.40 49.75 2.31 1.1521 1.1161
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Pos 2
Level 1 5% 25 (C)
What settings would you use for each variable? Cycle Time: Mold Temp.: Hold Press.: Hold Time:
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Design of Experiments
Pat Hammett
y2
Taguchi Experiments -- often do not use statistical inference to determine significance. Rather they compute signal to noise ratios for all variables and use settings which produce best ratios. Taguchi combines mean and variance into a single response -- traditional DOE separates them.
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Genichi Taguchi
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a Japanese engineer who has developed both philosophies and methodologies for quality improvement. often credited with playing a significant role in bringing statistically designed experiments to industry. his work has received strong reactions from academia and industry. Typical academic reactions to Taguchi in the use of:
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statistical techniques - much controversy over its lack of statistical rigor. quality engineering philosophy - much praise for its simplicity.
Industrial reaction to Taguchi Concepts n Taguchi concepts are often considered as more user-friendly than traditional design of experiments methods.
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