IE442:DesignandAnalysisof IE442: ExperimentsinEngineering Experiments in Engineering

Instructor:Prof.LinLi Instructor: Prof Lin Li

DepartmentofMechanical&IndustrialEngineering TheUniversityofIllinoisatChicago Email:linli@uic.edu; Office:3057ERF; Phone:3129963045(Office). ( )
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INSTRUCTOR Dr. Lin Li

EDUCATION Ph.D. (2007) Mechanical Engineering, University of Michigan, Ann Arbor, MI, USA Research Area: Sustainable Manufacturing Systems M.S.E. (2005) Industrial and Operations Engineering, University of Michigan, Ann Arbor, MI USA Ab MI, M.S.E. (2003) Mechanical Engineering, University of Michigan, Ann Arbor, MI, USA B.A. (2001) Business Administration, Shanghai Jiao Tong University, Shanghai, China B.E. BE (2001) Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, M h i lE i i Sh h i Ji T U i it Sh h i China PROFESSIONAL EXPERIENCE 1/2011 1/2011 present: A i t t P f t Assistant Professor, D t of M h i l & Industrial Engineering, Dept. f Mechanical I d t i l E i i University of Illinois at Chicago, Chicago, IL. 1/200912/2010: Assistant Research Scientist, Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI. 9/200712/2010: I t 9/2007 12/2010 Intermittent L t itt t Lecturer, D t of I d t i l and O Dept. f Industrial d Operations ti Engineering, University of Michigan, Ann Arbor, MI. 9/200712/2008: Postdoctoral Research Fellow, Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI. 9/20038/2007: 9/2003 8/2007 Research Assistant, NSF I/UCRC for Intelligent Maintenance R hA i t t f I t lli tM i t Systems, and S. M. Wu Manufacturing Research Center, Dept. of Mechanical Engineering, University of Michigan, Ann Arbor, MI.
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SyllabusIntroduction

Introduce yourself to others y (1 minute)

Name Department and Major Undergraduate or graduate students Other Background and more?

CourseTopics Course Topics

Introduction(Ch1) SimpleComparativeExperiments(Ch2)
Hypothesistesting

Experiments with Single Factor (Ch3) ExperimentswithSingleFactor(Ch3)

AnalysisofVariance

RandomizedBlockDesigns(Ch4) FactorialExperiments(Ch5Ch7) FractionalFactorialExperiments(Ch8) MultipleLinearRegression(Ch10) Multiple Linear Regression (Ch10) ResponseSurfaceExploration(Ch11)

StrategyofExperimentation Strategy of Experimentation

Why do we experiment? Whydoweexperiment?
Discoversomethingaboutaprocessorsystem Anexperimentisatestoraseriesoftest p

Howdoweexperiment?
Changes made in the input variables to identify Changesmadeintheinputvariablestoidentify changesintheoutput

Where?
virtuallyallfields,inengineeringsometimeswe lookforrobustnessinaprocess
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Planninganexperiment Planning an experiment

Vi li i Visualizingaprocessorsystem t

Controllable Factors x Input Variables w

1 1

PROCESS
r

Output Variables y
1

...

...

z1

z2

Uncontrollable Factors

Objectivesoftheexperiment Objectives of the experiment

Determine which variables are most Determinewhichvariablesaremost influentialonresponse Determinewheretosettheinfluentialx sso Determine where to set the influential xs so thattheoutputisinadesiredvalue Determinewheretosettheinfluentialx sso Determine where to set the influential xs so thatthevariabilityoftheoutputissmall Determinewheretosettheinfluentialx sso Determine where to set the influential xs so thattheeffectsofuncontrollablevariablesare minimized
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SystematicApproach Systematic Approach

ExperimentalDesignisasystematicapproachto Experimental Design is a systematic approach to understandinginterrelationshipsinorderto 1.Improveyield 1 Improve yield 2.Reducevariability 3.Reducedevelopmenttime 4.Reducecost

ExamplesofExperiments(textbook) Examples of Experiments (textbook)

Example1 1:CharacterizingaProcess Example 11: Characterizing a Process SolderingPrintedCircuitBoardsExample Example12:OptimizingaProcess l 2 O i ii ChemicalYieldExample Example13:AProductDesignExample Automotive Door Hinge Example AutomotiveDoorHingeExample

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GuidelinesforDesigningExperiments Guidelines for Designing Experiments

Recognition/definitionoftheproblem Recognition/definition of the problem Choiceoffactors,levelsandranges Selectionoftheresponsevariable S l i f h i bl Choiceofexperimentaldesign Performingtheexperiment Statisticalanalysisofthedata Statistical analysis of the data Conclusionsandrecommendations
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UsingStatisticalTechniques Using Statistical Techniques

Use your nonstatistical knowledge of the Useyournon statisticalknowledgeofthe problem! Keep the design as simple as possible Keepthedesignassimpleaspossible Recognizethedifferencebetweenpractical andstatisticalsignificance d i i l i ifi Experimentsareusuallyiterative

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BriefHistoryofStatisticalDesign Brief History of Statistical Design

Agricultural era: pioneering work by Ronald Fisher, Agriculturalera:pioneeringworkbyRonaldFisher, 1920sandearly1930s Industrialera:responsesurfacemethodologybyBox p gy y andWilson,1950s.Optimaldesignofexperiments began. Thirdera:interestforqualityimprovement.Robust parameterdesignbyTaguchi,late1970s Fourthera:basedonthethirdera,developmentof newandusefulapproachestoexperimental problemsintheindustrialworld,1990s bl i th i d t i l ld 1990
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Statistical Quality Control Methods Q y

Three major quality control methods are SPC, DOE (design of experiments), and acceptance sampling. IE446 will cover two of them: SPC and acceptance sampling. This course will cover DOE. A simple example to illustrate the three methods: A typing example. l

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Typing Example
Consider improvement of typing quality, which is measured by typing accuracy and clearness. Acceptance sampling Several sample pages are inspected from every lot (for example, every 100 typed pages). If the selected sample pages have satisfactory quality, the whole lot is accepted. Otherwise, the whole lot is rejected and rework should be done. Statistical process control (SPC) Every hour one page is selected and its quality is measured. Plot the measurements from each hour on a control chart. If a shift of quality is detected, the root cause of this shift (such as typist tiredness, lack of ink) is identified and fixed. Design of experiment (DOE) Conduct experiments with combinations of different typists, typewriters, papers, working schedules. The best combination of these factors are selected to achieve optimal typing quality.

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