Quality Improvement

through Planned
Experimentation
Third Edition

Ronald D. Moen
Thomas W. Nolan
Lloyd P. Provost

Me
Graw
Hill
New York Chicago San Francisco
Lisbon London Madrid Mexico City
Milan New Delhi San Juan
Seoul Singapore Sydney Toronto

CONTENTS

Foreword

CHAPTER 1

Preface

xv

Acknowledgments

xix

Improvement of Quality
1.1
1.2

CHAPTER 2

xiii

Introduction
Building Knowledge and the Scientific
Method
1.3 Defining Quality
1.4 Model for Improvement
1.5 Sequential Experimentation Using
the PDSA Cycle
1.6 Summary.;
References
Exercises

19
21
22
23

Principles for Design and Analysis of

Planned Experiments

25

2.1 Introduction and Definitions

2.2 Types of Planned Experiments
2.3 Principles for Designing Analytic
Studies
2.4 Tools for Experimentation
2.5 Form for Documentation of a Planned
Experiment
2.6 Analysis of Data from Analytic Studies
2.7 Summary
References
Exercises

1
2
4
9

25
29
34
40
y 51
54
58
58
59
VII

VIII

Contents

CHAPTER 3

Experiments with One Factor

63

3.1

CHAPTER 4

CHAPTER 5

General Approach to One-Factor

Experiments
3.2 Using Run Charts for a One-Factor
Design
3.3 Using Shewhart Charts for One-Factor
Experiments
3.4 Paired-Comparison Experiments
3.5 Randomized Block Designs
3.6 Incomplete Block Designs
3.7 Summary
References
Exercises

76
79
85
95
103
104
104

Experiments with More Than One Factor

109

4.1 Introduction to Factorial Designs

4.2 Design of Factorial Experiments
4.3 Advanced Topics in the Analysis of
Factorial Experiments
4.4 Summary
References
Exercises

Ill
136
142
156
156
156

Reducing the Size of Experiments

161

Introduction to Fractional Factorial

Designs
5.2 Fractional Factorial DesignsModerate
Current Knowledge
5.3 Fractional Factorial DesignsLow
Current Knowledge
5.4 Using Blocking to Design a Sequence of
Experiments
5.5 Summary
Appendix: Development of Other Blocking
Arrangements

64
68

5.1

163
170
183
? 192
202
204

Contents

CHAPTER 6

CHAPTER 7

| ix

References
Exercises

206
207

Evaluating Sources of Variation

211

6.1 Applications of Nested Designs

6.2 Planning and Analyzing an Experiment
with Nested Factors
6.3 More Complex Nested Designs
6.4 Summary
Appendix 6 A: Calculation of Variance
Components
Appendix 6B: Calculating and Combining
Statistics (X, S, or R)
References
Exercises

213

244
245
245

Sequential ExperimentationA Case Study

251

7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9

Improving a Milling ProcessGetting

Started
The First Improvement Cycle: Current
Performance of the Mills
The Second PDSA Cycle: Sources
ofVariation..
The Third PDSA Cycle: Evaluating Mill
Cutter Vendors
The Fourth PDSA Cycle: Screening Process
Variables
The Fifth PDSA Cycle: Evaluate Effect of
Improvements on the Mill Process
The Sixth PDSA Cycle: Evaluating
Important Factors
The Seventh PDSA Cycle: Determining j
Optimum Levels
The Eighth PDSA Cycle: Confirmation
of Improvements

221
227
238
238

251
255
261
263
265
269
270
275
277

Contents

7.10

CHAPTER 8

Final Actions of the Mill Improvement

Team
Exercises

277
280

Using a Time Series Response Variable

281

8.1

Incorporating Experimental Patterns

in a Time Series
8.2 Shewhart Charts
8.3 Designs for Sequential Experimentation
Using Time Series Response Variables
8.4 Summary
References
Exercises
CHAPTER 9

Experiments with Factors at More Than

Two Levels
Factorial Designs with More Than Two
Levels
,
k
9.2 Augmenting 2 Factorial Designs with
Center Points
9.3 Three-Level Designs for Quantitative
Factors
9.4 Experiments for Formulations or
Mixtures
9.5 Experimental Designs for Complex
Systems
9.6 Summary
References
Exercises

281
286
295
303
303
304

309

9.1

CHAPTER 10

Applications in Health Care

10.1 Introduction
10.2 Applications
10.3 Summary
References
Exercises

309
316
321
326
337
341
342
342
345
J346
350
365
.. 366
367

Contents

CHAPTER 11

XI

New Product Design

369

11.1 Introduction
11.2 Phase 0: Generate Ideas
11.3 Phase 1: Develop Concepts and
Define Product
11.4 Phase 2: Test
11.5 Phase 3: Produce Product
11.6 Summary
References
Exercises

369
372

APPENDIX A Evaluating Measurement Systems

377
397
413
414
415
416
417

Glossary

457

Index

465