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Shainin’s Methods Practical Design of Experiment

Shainin’s DOE Tools

I List of Clue-Generating Tools

a. Multi-Vari Analysis II. Formal Design of Experiment
b. Concentration Charts Technique to Characterize a
c. Component Search Product / Process
d. Paired Comparison a. Variable Search
b. The Full Factorial
e. Product/Process Search
c. B versus C

III. DOE Optimization

a. Scatter Plot - to Achieve Realistic
Specification and Tolerances

b. Response Surface Method

V. Transition from DOE to
(RSM) - to Optimize Interactions
Statistical Process Control

a. Positrol:
Holding the gains

B. Process Certification:
Eliminating Peripheral
Causes of Poor Quality
Statistical Process
Control:

a. Pre-control
Simple & effective technique
of Process Control

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I List of Clue-Generating Tools
a. Multi-Vari Analysis
b. Concentration Charts
c. Component Search
d. Paired Comparison
e. Product/Process Search
CLUE GENERATION TOOLS
Multi-vary • to reduce a larger number of unknowns and unmanageable causes of variation into a much
Experiments
smaller of related variables containing the Red X (i.e most dominant cause.)
• It is a graphical technique to zoom in to the most likely cause of the problem by eliminating
non-contributing causes of variation.
• In most application, multi-vari technique acts as the first filter which later followed by other
clue generation tools.

Concentration • Sequel to Multi-vary Experiments. It is used to pinpoint repetitive defects

Charts
by location or components
• Determines how a product/process is running; a quick snapshots without massive historical
data and can be substitute for replace process capability studies in some white collar
applications
• Normally used when the Red X is “ within-unit”
• Min 9 to 15 or until 80% of historic variation is captured.

Component • From hundred of thousands of components/ subassemblies, home in the Red X, capturing
Search
the magnitude of ALL important main effects and interaction effects.
• Normally used when there are two differently performing assemblies ( labeled as “good”
and “bad”) with interchangeable components (electric motors, suspension system of a
car..)
• Typically use at prototype, engineering pilot run, production pilot run, or in field.
• Require only 2 samples – One(1) “good” unit and one(1) “bad” unit

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CLUE GENERATING TOOLS

Paired Comparison • Used to identify the Red X when the good and bad units, assembly or
subassembly cannot disassemble and reassemble without damaging or
destroying or radically changing the good and bad units properties.
• Use in situation where there are two differently performing assemblies (
labeled as “good” and “bad”) incapable of interchangeable of the
components.
• Commonly used in New product and/or process design production, field,
support services, administrative works, farms, hospital, and schools.
• It is a logical sequence to component search, when the Red X, distilled
from the system, subsystem, and subassembly component search, cannot
be disassemble any further.
• Sample size required : 12 to 16 - 6 to 8 “good” units and 6 to 8 “bad”
units in rank order.

Product Process Search •To identify important product variables identified with paired comparison.
• To identify important process variables associated with 8 good and 8 bad
products.
•Commonly used in situation where it is difficult to isolate important process
variables with multi-vari
•Typically used during prototype, engineering pilot run, production pilot run,
in field or in full production
•Sample size required: Sufficient units through a process to produce 8
“good” units and 8 “bad” units and their associated process parameters

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Technique to Characterize a
Product / Process
a. Variable Search
b. The Full Factorial
c. B versus C

FORMAL DESIGN OF EXPERIMENT TECHNIQUES

Variable Search •Excellent problem prevention tools normally used to Pinpoint the Red X,
PUREST Pink X etc.
•Full Factorial • Capture the Magnitude of all important main effects and interaction
•Variable Search effects. Of the red X, pink X etc.
•Latin Square • To identify any unimportant factors so that their tolerances can be
•Plackett-Burman liberated to reduce cost.
•Fractional Factorial • Normally used when there are High Number of variable to investigate (
•Taguchi Orthogonal 5 to 20 variables).
Array • Application in white collar work (off-line quality control).
•Typically used in R& D , Development engineering, Product Process

Most CONTAMINATED Characterization in Production .

• For pinpointing the Red X after Multi-Vari or Paired Comparison
experiments have been conducted.
•Sample Size required - 1 to 20

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FORMAL DESIGN OF EXPERIMENT TECHNIQUES

B versus C • Basically used as Verification Tool.

• To predict how much better a given product or process is than
another, with confidence of 90% or higher.
• To assure the permanency of an improved product or process over a
previous one.
• To select one product or process over another, even if there is not
improvement in quality, because of some tangible benefits, such as
cost or cycle time.
•To evaluate more than just two product, processes, materials
(B,C,D,E etc) simultaneously

Full Factorial •To determined which of the 2,3 or 4 variables - filtered through one
or more clue-generation techniques- are important and which are
unimportant;
•To open up tolerance of the unimportant variables to reduce costs;
•To quantify the magnitude and desired direction of the unimportant
variables and their interaction effects, and to tighten the tolerance
of these variables to achieve a Cp, Cpk = 2.00 and more;
•Investigative tool at design or prototype stage where samples
are limited for other clue-generating tools.;
•Note: Even though Full factorial experiment is a problem-solving
tool, it is not recommended to use it as a start of a problem
investigation bypassing other clue generation tools.

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III. DOE Optimization
a. Scatter Plot - to Achieve Realistic
Specification and Tolerances

b. Response Surface Method

(RSM) - to Optimize Interactions

DOE FOR OPTIMIZATION

Scatter plot •Used to establish Realistic Specifications and Realistic Tolerances.
• Used to adjust or Tighten the Tolerances of the important
product/process or Red X variables to achieve high Cpk’s.
• Open up the Tolerances of the unimportant variables to reduce cost.

Response Surface Methods •To determine the BEST combinations of levels of two or more
(RSM)
INTERACTING input variables ( identified in previous DOE
experiments) to achieve a maximum, minimum , or optimum Green Y
( Response, output and Green Y are the same terms).

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V. Transition from DOE to
Statistical Process Control
Vi) Statistical Process
a. Positrol:
Control: Holding the gains
a. Pre-control
Simple & effective technique B. Process Certification:
of Process Control Eliminating Peripheral
Causes of Poor Quality

TRANSITION FROM DOE TO SPC

Positrol The POSITROL plan determines:
a) WHAT the variable characterized and optimized through
previous DOE experiment.
B) WHO should be performing the monitoring, measuring and
recording each of important variables.
C) HOW determines the correct instrumentation to measure
these important variables( observing the 5:1 rule ).
D) WHERE determine optimum location of measuring the
process parameters so that it truly reflects the correct value.
E)WHEN is the frequency of measurement, determine initially
by engineering judgment, but later by pre-control.
Process Certification •Use process certification to eliminate the Peripheral Causes of
Variation and Poor Quality such as:
•Management/supervision inadequacy
•Violation of Good Manufacturing Practices (GMP)
•Plant/Equipment inattention
•Environment Neglect
•Human Shortcomings

STATISTICAL PROCESS CONTROL

SPC: Pre-Control • The use of simple and cost effective pro-control chart and reaction
plan to ensure the process sustain the improvement achieved.
•Typically at the last stage of improvement process.

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Problem Solving Framework - linking all the Shainin’s Tools
Problem Solving Steps
1.Define the problem
( Green Y)
2. Quantify and measure the
Green Y
3.Problem History (problem
history, defect rate, cost)
4.Generate Clues
5.Formal Design of Experiment
(DOE)
6. Turn Problem on and Off –
ensuring permanence of
improvement
7. Establish realistic specification
and Tolerances (optimize)
8. 8. “Hold” the process
improvement gains
9. Hold the Gain with SPC
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Objectives Common Shainin’s DOE Tools
•Proper Understanding and defining
the problem at hand.
•To pinpoint the problem •Measure scatter plot
•Improve the resolution of the •Use Likert Scale to convert
problem attributes into variables
•Understanding historical •Trends (Pareto, Defect rate,
background of the problem Cost )
•To identify all possible causes of the •Multi-vari ( including
problem and sources of variation concentration chart)
•To identify the possible • Component Search
variables/factors related to the •Paired Comparison
problem •Product/Process Search
•To identify the possible process •Variable Search
variables/factors related to the • Full Factorial
problem • B vs.C
•To identify the possible
parts/components related to the
problem
•To validate the possible > B vs. C
parts/components related to the
problem
•To specified the optimize the Red X • Scatter Plot
( significant cause(s) ) with proper • Response Surfaced Method
tolerances. (RSM)
•To maintain the improvement •Positirol
achieved through well defined series
of control mechanisms
•Manage the improved / validate Pre-control
process
•Daily management of the process
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Relationship between Green Y and Red X : Pareto Principle

Green Y
50% The Vital Few
The Trivial Many

1 2 3 4 5 6 7
Causes/variable/factors/component/parts

Red X
Pink X
Pale Pink X
Note: Solving for the Red X, Pink X and Pale Pink X can:
1. Reduce variation
3. Eliminate the Green Y (problem)
2. Achieve Cpk of 2.00 to 10.00 with one, two or three experiments

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Engineering Shainin’s Methods Problem Solving Steps
Searching For Red X: Problem Solving Steps

Problem Green Y

Measurement System /Discrimination Ratio Accuracy, Bias ,precision

5:1 Accuracy
Scatter Plot/Multivari
•Within Instruments
Variation Family •Instrument-to-instruments
Known? •Operator-to-operator
•Likert Chart
1
Multi-Vari
Experiment

N Within Unit N
Unit-to-Unit variation Time-to-Time
variation variation

2 Y Y
Y
Component Y
search Experiment

Assemble/
Next Next
Reassemble
page page

Progressive N Green Y Y Part/Component Related

Disassembly Constant?
3
Paired Comparison
4 5
Variable Search
Full Factorial N Red X
Y B vs.C
Experiments Experiment
Identified?

5 4
Response Surface Y Interaction N Scatter-Plot
Experiment
Method Experiment
present?

6
Positrol Process
Certification

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Shainin’s Methods Problem Solving Steps
Searching For Red X: Problem Solving Steps

From
Previous
Page

N N Time-to-Time
Within Unit
Unit-to-Unit variation variation
variation

Concentration
Chart
Next
Refer to page
Previous
Page
Paired
Comparison

Variable Search N Y B vs.C

Full Factorial Red X
Identified? Experiment
Experiments

Response Surface Y N ScatterPlot

Method Experiment Interaction
present? Experiment

Positrol Process
Certification

Pre-control

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Shainin’s Methods Problem Solving Steps
Searching For Red X: Problem Solving Steps

From
Previous
Page

Unit-to-Unit Time-to-Time
Within Unit
variation variation
variation

Refer to Refer to
Previous Previous
Page Page
Product
Process Search

Variable Search N Y
Red X B vs.C
Full Factorial
Identified? Experiment
Experiments

Response Surface Y Y ScatterPlot

Interaction
Method Experiment Experiment
present?

Positrol Process
Certification

Pre-control

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