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Black Belt Intermediate
Tools/Refresher Training

DOE for Variance Reduction
and Robust Design
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DoE Analysis Methods















Advantages
Gives you the m & s model and the interactions
Provides built in sensitivity analysis
Can provide a good estimate of m & s over the selected range
of independent variables
Disadvantages
Number of runs can be expensive if doing in hardware
Extrapolation outside model is a extremely risky
IVs DVs
y = b
0
+ b
1
A + b
2
B

+ b
3
AB

+ b
4
A
2
+ . . .
s = w
0
+ w
1
A + w
2
B

+ w
3
AB

+ w
4
A
2
+ . . .
^
^
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Potential DoE applications
System Characterization

Flowdown of Requirements

System Optimization
Robust Design

Simulation Efficiency

Algorithm Development

Transfer Function Definition
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Robust DoE with Outer Array Noise
USL LSL
{
Range of
Possible
Inputs
X
1
X
2
Y
=
f
(
X
1
,
X
2
.
.
.
)

Y
Noise
Env. Variables
Design Simulator
Using a design simulator/model
Systematically vary the inputs using DoE
Systematically vary the noise and environmental factors
or
Allow either one of them to vary randomly or using Monte Carlo
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Robust Design using DoE
A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
Inner
orthogonal
array
Variation due to
noise and IV
errors
y = b
0
+ b
1
A + b
2
B

+ b
3
AB

+ b
4
A
2
+ . . .
s = w
0
+ w
1
A + w
2
B

+ w
3
AB

+ w
4
A
2
+ . . .
^
^
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Setting up a Robust DoE in Minitab (3
factor example)
Set up the DoE from the previous page the same as discussed in DoE training
The Inner Orthogonal Array looks exactly like
our previous DoEs
Gather multiple responses
with each run. Y1, Y2, and
Y3 These columns must be
entered manually.
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Analysis of the Data
Utilizing Row Statistics for the multiple responses, calculate the Mean and Standard Deviation
for each run
Analyze the DoE as you normally would, first using Mean_Y as the response and then
using SD_Y as the response.
The DoE results will provide you with an Y-hat and S-hat equation
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EXERCISE: Robust Design
Your job is to design a catapult that will throw any of three balls (nerf, wiffle, or rubber) the same distance.
Your goal is to select and fix the proper setting for Pull Back Angle and Stop Angle such that any of the three
balls will always fly the same distance +/- 6 inches. However, your design will also be judged by how far the
balls fly. The farther the balls fly the higher the price the customer will pay.
Using the Catapult, (or substitute data) build a y-hat and s-hat model using different ball types. Make the
design robust to ball type using an outer array design. Specifications are +/- 6 accuracy. Confirm your results.
Use Pull Back Angle and Stop Angle as the two Independent Variables
Use a Wiffle, Nerf, and Rubber ball as the noise variables.
Fix the other setting for the Catapult as follows
Cup Height = 1 Hook position = 5
Pin Position = 4 Number of RBs = 1
Your Minitab table should look something like this
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Handling Random Noise as a Result of
Noise Inputs
A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
y = b
0
+ b
1
A + b
2
B

+ b
3
AB

+ b
4
A
2
+ . . .
s = w
0
+ w
1
A + w
2
B

+ w
3
AB

+ w
4
A
2
+ . . .
1
Inner
orthogonal
array
Variation due to H,
I, and J; random
variables
Monte Carlo
Based Sampling
strategy
^
^
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Random Noise thru Systematic Variation of
Noise Variables
2
H
I
J
Outer
orthogonal
array
A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
Inner
orthogonal
array
H
I
J
+ + + ........
- + + ..........
+ - + .........
- - + ..........
+




+





+

-





+





+

+




-






+

-





-






+

+




+





-

-





+





-

+




-






-

-





-






-

A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
Variation due to H,
I, and J; random
variables
Variation due to
systematic sampling of
H,I, & J
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Varying the Independent Variables with
Monte Carlo
3
Variation due to A
through G
tolerances
Monte Carlo Based
Sampling strategy
y =
s =
^
^
- 1 A + 1
A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
Inner
orthogonal
array
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Handling Variances in the Independent
Variables with DoE
4
Outer orthogonal
array
- 1 A + 1
^
y = s =
^
A B C . . . . . G Y
1
Y
2
. . . . . Y
n
Y-bar s
Inner
orthogonal
array
Variation due to
systematic sampling of
A - G
A
B
...
G
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Handling Variances in Simulation DoEs
5
A B C . . . . . G Y
Inner
orthogonal
array
y =
^
Can have combinations of options 1 - 4
6
Estimates by considering component
variations in Y-hat
Differentiate Y-hat and estimate variance
Using non-replicated designs
Test Tolerances
Determine Y
max
and Y
min


S = (Y
max
- Y
min
) / 6
+ / - Settings are
tolerances of A -
G
A B C . . . . . G Y
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DoE Applications Using
Prototypes
Assessing robustness and building empirical models from
prototypes is possible.
Must be able to actually vary the Independent Variables and assess
the effect on the response.
Assess product reliability
A good way to build low fidelity models for predicting and optimizing
system performance.
Examples of Prototype opportunities






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2
2
Full Factorial
3 Replicates
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Multiple Response
Optimization Tool
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Checking for Variance Shifting Factors:

STAT>
ANOVA>
HOMOGENEITY
of VARIANCE
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Evaluate each
term
independently
for effects on
Std. Dev.
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Check the dot product
columns for interaction
effects