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Design of Experiments - Tool

Design of experiments (DOE) is a tool used to optimize products and processes, accelerate development cycles, and reduce costs. It involves statistically designing experiments to simultaneously consider all factors that could impact quality, even interactions between factors. This is more efficient than traditional one-variable-at-a-time experiments, and allows for a valid evaluation of main effects. Proper planning of experiments includes selecting the study area, proving the need for experimentation, identifying all possible factors, and determining the appropriate response and model for analysis.

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653 views17 pages

Design of Experiments - Tool

Design of experiments (DOE) is a tool used to optimize products and processes, accelerate development cycles, and reduce costs. It involves statistically designing experiments to simultaneously consider all factors that could impact quality, even interactions between factors. This is more efficient than traditional one-variable-at-a-time experiments, and allows for a valid evaluation of main effects. Proper planning of experiments includes selecting the study area, proving the need for experimentation, identifying all possible factors, and determining the appropriate response and model for analysis.

Uploaded by

muneerpp
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Design of experiments

Design of experiments

Design of experiments (DOE) is a valuable tool to:-


Optimize product and process designs
Accelerate the development cycle
Reduce development costs
Improve the transition of products from research and
development to manufacturing
Effectively trouble shoot manufacturing problems.

Today, Design of Experiments is viewed as a quality


technology to achieve product excellence at lowest
possible overall cost.
Objectives of Experimentation

The following are some of the objectives of


experimentation in an industry :
■ Improving efficiency or yield
■ Finding optimum process settings
■ Locating sources of variability
■ Correlating process variables with product
characteristics
■ Comparing different processes, machines, materials etc
■ Designing new processes and products.
Various terms used in Experimentation

In the context of discussion on experimental


designs, the common frequently used terms
are :
■ factor
■ Level
■ Treatment combination
■ Response
■ Effect
■ Interaction
Traditional approach

The traditional approach to product and process


optimization is to conduct one variable at-a-time
experiments. This approach though simple to plan and
execute, suffers from several drawbacks. For instance,
varying factor ‘A’ from its nominal value ‘A1’ to some
other value ‘A2’ may produce a given change in the
quality of the product, when other factor ‘B’ is at a
value ‘B1’. However a different change in the quality of
the product will result, when factor ‘B’ is at a value
‘B2’. This effect known as interaction effect, can not
be detected under traditional approach..
Statistically designed experiments

A statistically designed experiment permits simultaneous


consideration of all the possible factors that are suspected to
have bearing on the quality problem under investigation and
as such even if interactions effect exist, a valid evaluation of
the main effect can be made. Scanning a large number of
variables is one of the ready and simpler objectives that a
statistically designed experiment would fulfill in many problem
situations.
Statistically designed experiments

Even a limited number of experiments would enable the


experimenter to uncover the vital factors as which further
trials would yield useful results. The approach has number of
merits, it is quick, reliable and efficient.
Basic principles of experimentation

Basic principles of Experimentation are :


■ Randomization
■ Replication
■ Local Control
Basic principles of experimentation

■ Randomization : is described as an insurance against


extraneous factors.
■ Replication : increases the sensitivity of the experiment i.e
power of detecting differences between treatments.
■ Local Control : reduces the effect of natural variability of
materials, environmental conditions etc.
Planning for experimentation

It is known widely that a properly well planned experiment


helps to achieve better efficiency and hence certain amount of
thinking must be done before deciding to carry out the
experiment and actually conducting the experiment.
Planning for experimentation

The various steps to be followed in this direction are


listed below :
 Selection of area of study : Pareto analysis
 Proof of the need for experimentation
 Brain storming and Cause & Effect diagram : To list all
the possible factors
 Classification of factors
 Interactions to be studied
 Response and type of model for analysis

Note : Pareto Analysis, Brain storming and Cause & Effect


diagrams have already been covered in the previous slides.
Proof of the need for experimentation

After having selected the area for experimentation we


have to ensure that the problem is of ‘Break through’ or
‘Improvement’ nature and not a problem of ‘control’
nature. For this purpose past data should be suitably
analyzed and plotted on some process control chart to
check whether the process is within statistical control or
not. If the analysis shows lack of control or statistical
instability, then it is a problem of ‘control’ nature and
experimentation may not be needed.
Proof of the need for experimentation

However if the problem is of chronic nature and there is


stability in the process, then it establishes the need for
experimentation. Before deciding to carry out
experimentation the need for experimentation must be
established.
Classification of factors

Tools like brainstorming and cause & effect diagrams helps in


identification of factors and preparing a complete list of the
factors involved in any experiment. Factors listed can be
classified into three categories :
1. Experimental Factors
2. Control Factors
3. Error or Noise Factors
Classification of factors

1. Experimental factors are those which we really


experiment with by varying them at various levels.
2. Control Factors are those which are kept at a
constant (controlled) level throughout experimentation.
Classification of factors

3. Error or Noise factors are those which can neither be


changed at our will nor can be fixed at one particular level.
Effect of these factors causes the error component in the
experiment and as such these factors are termed as error or
noise factors.

Note : At the planning stage itself all the factors viz.


Experimental, Control and error should be recognized.
This will help to tackle them appropriately during
experimentation.
Response and type of model for analysis

The ultimate observations or data generated by the


experiment is known as the response. The response may be
:
■ Continuous or measurement type and follows a normal
distribution
■ Continuous or measurement type but does not follow normal
distribution

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