CH 3 TTA Experimental Design-1

Dr.
Mohammad Aliedeh
Interactions
in Processes
Dr. Mohammad Aliedeh
Problem (2) : The grades of Two chemical engineering students (Oglah and Falhan)
are studied by implementing the following 23 full factorial design. Use Minitab
Software to analyze these data and then fully discuss the results of the analysis
including if there is a suspicion of cheating committed by any of the two students.
Exam Seat Position Course Oglah Falhan
First Closely Seated Mass Transfer 75 92
Second Closely Seated Mass Transfer 82 85
First Front Seated Mass Transfer 27 87

Second Front Seated Mass Transfer 35 91
First Closely Seated Heat Transfer 85 84
Second Heat Transfer 79 79
Closely Seated
Heat Transfer 18 94
First Front Seated
Second Front Seated Heat Transfer 22 86

Estimated Effects and Coefficients for Oglah (coded units)
Term Effect Coef

Constant 52.88
Exam 3.25 1.62
Seat Position -54.75 -27.37
Course -3.75 -1.87
Exam*Seat Position 2.75 1.38
Exam*Course -4.25 -2.12
Seat Position*Course -7.25 -3.63
Estimated Effects and Coefficients for Falhan (coded units)
Term Effect Coef

Constant 87.250
Exam -4.000 -2.000
Seat Position 4.500 2.250
Course -3.000 -1.500
Exam*Seat Position 2.000 1.000
Exam*Course -2.500 -1.250
Seat Position*Course 4.000 2.000
3 Understanding Key Interactions in Processes 3

1. This chapter illustrates the significance of
interactions in industrial processes and how to
deal with them.
2. In order to study and analyse interactions
among the process or design parameters, we
Keywords
have to vary them at their respective levels
Interactions;
simultaneously.
synergistic interaction;
3. In order to understand the presence of
antagonistic interaction;
interaction between two process parameters,
interaction plot;
it is encouraged to employ a simple and
interaction effects
powerful graphical tool called an interaction
graph or plot.
4. If the lines in the plot are parallel, it implies
no interaction between the process
parameters.
5. In contrast, non-parallel lines are an indication
of the presence of interaction.
6. This chapter also presents two scenarios for
better and more rapid understanding of how
to interpret interactions in industrial
experiments.
3. Understanding Key Interactions in Processes
3
3.4 Scenario 1
3.1 Introduction
3.5 Scenario 2
3.6 Scenario 3
3.2 Alternative Method for 3.3 Synergistic

Calculating the Two-Order Interaction Versus
Interaction Effect Antagonistic Interaction
3 Understanding Key Interactions in Processes
3
1. This chapter illustrates the significance of interactions in industrial processes and how to deal with them.
2. In order to study and analyse interactions among the process or design parameters, we have to vary them at their
respective levels simultaneously.
3. In order to understand the presence of interaction between two process parameters, it is encouraged to employ a
simple and powerful graphical tool called an interaction graph or plot.
4. If the lines in the plot are parallel, it implies no interaction between the process parameters.
5. In contrast, non-parallel lines are an indication of the presence of interaction.
6. This chapter also presentstwo scenarios for better and more rapid understanding of how to interpret
interactions in industrial experiments.
Keywords
Interactions Main Effects
interaction effects
interaction plot
Antagonistic Synergistic
Interaction Interaction
Wave-Soldering Process
3
Wave soldering is a bulk soldering process used in the manufacture of printed circuit boards. The circuit board is
passed over a pan of molten solder in which a pump produces an upwelling of solder that looks like a standing wave.
As the circuit board makes contact with this wave, the components become soldered to the board. Wave soldering is
used for both through-hole printed circuit assemblies, and surface mount. In the latter case, the components are
glued onto the surface of a printed circuit board (PCB) by placement equipment, before being run through the
molten solder wave. Wave soldering is mainly used in soldering of through hole components.
3.1 Introduction
3
3.2 Alternative Method for Calculating the Two-Order Interaction Effect
3
3.3 Synergistic Interaction Versus Antagonistic Interaction
3
Homework (3): Study the following 8 Different Interaction Patterns, comment on them and arrange
them in the order of increasing interaction and explain the concept of interaction and your reasoning
(a) (b) (c)
A×
×B A×
×B
A×
×B
B+ B+
B+
y y
y
B-
B- B-
A- A+ A- A+
A- A+
(d) (e) (f)
A×
×B A×
×B
A×
×B
B+ B+
B+
y y
y
B- B-
B-
A- A+ A- A+
A- A+
3.4 Scenario 1
3
3.5 Scenario 2
3.6 Scenario 3
Box, G. E. P., Hunter J. S., and Hunter

W. G., (2005). Statistics for
experimenters: design, innovation,
and discovery, 2nd Edition, London:
Wiley-Blackwell.
Exp. Design HO 01 Dr. Mohammad Aliedeh
Generic 22 Full Factorial Design Matrix y3
Exp. # A B A×B y y3 y4-y3 y4 y4

1 -1 -1 +1 y1
B+
2 +1 -1 -1 Y2
3 -1 +1 -1 Y3 y3-y1 y4-y2
4 +1 +1 +1 Y4
B- y1
y1 y2-y1 y2
Difference Shows Effects
A- A+ y2
and Average hide effect
Effects Explanations Short Cut Method
Revealing A Effect by Difference Revealing B Effect by Difference

-y1+y2-y3+y4
y2-y1 y4-y3 y3-y1 y4-y2
A=
+ + 2
A= B= Main
2 2
Effects
Hiding B Effect by Average Hiding A Effect by Average -y1-y2+y3+y4
B=
Revealing B Effect by Difference Revealing A Effect by Difference
2
y4-y2 - y3-y1 y4-y3 - y2-y1 y1-y2-y3+y4

B×A= A×B= B×A= A×B=
2 2 2
Interaction
Effect
Dr. Mohammad A. Aliedeh 01
Exp.
B A A×B y
y3 y4-y3 y4 y4
# B+
1 -1 -1 +1 115.84
2 +1 -1 -1 106.74 y3-y1 y4-y2
3 -1 +1 -1 116.84
4 +1 +1 +1 124.3 B- y1
y1 y2-y1 y2
Difference Shows Effects
A- A+ y2
and Average hide effect
Effects Explanations Short Cut Method

-115.84+106.74-
116.84+124.3
-0.82
y2-y1 y4-y3 y3-y1 y4-y2
A=
+ + 2
A= B= Main
2 2
Effects
Hiding B Effect by Average Hiding A Effect by Average -y1-y2+y3+y4
B= 9.28
Revealing B Effect by Difference Revealing A Effect by Difference
2
y4-y2 - y3-y1 y4-y3 - y2-y1

B×A= A×B= B×A= A×B=
y1-y2-y3+y4 8.28
2 2 2
Interaction
Effect
A Main Effect Plot

y3 y4-y3 y4
B+
y3-y1 y4-y2
B-
y1 y2-y1 y2
116.34
A- A+
115.52
Revealing A Effect by Difference
y2-y1 + y4-y3
A=
A- A+ 2
Hiding B Effect by Average
y 2 + y 4 y1 + y 3
A= −
2 2
A = 115.52 − 116.34 = −.82
Main Effect Plot
A- A+ A- A+ A- A+
A- A+
A- A+
y3 y4
B+=7.46 y4 B+
y4-y3
y3-y1 y4-y2
y3 B-
y1 y2-y1 y2
y1 B-=-9.11 A- A+
y2 Revealing A Effect by Difference
y4-y3 - y2-y1
A×B=
2
A- A+ Revealing B Effect by Difference
8.28
(1)
A- A+ A- A+ A- A+
A- A+
A- A+
Pilot Plant Performance Experiments

23 Full Factorial Design Matrix
Coded (Main
Uncoded Interaction Effects Interaction Effects
Effects)
Exp. # T C K T C K T×C C×K T×K T×C×K y y

1 -1 -1 -1 25 2 M +1 +1 +1 -1 y1 60
2 +1 -1 -1 75 2 M -1 +1 -1 +1 Y2 72
3 -1 +1 -1 25 5 M -1 -1 +1 +1 Y3 54
4 +1 +1 -1 75 5 M +1 -1 -1 -1 Y4 68
5 -1 -1 +1 25 2 C +1 -1 -1 +1 Y5 52
6 +1 -1 +1 75 2 C -1 -1 +1 -1 Y6 83
7 -1 +1 +1 25 5 C -1 +1 -1 -1 Y7 45
8 +1 +1 +1 75 5 C +1 +1 +1 +1 y8 80
23 -5 1.5 1.5 0 10 0.5
Dr. Mohammad A. Aliedeh σ= ± 3 02

Center Points
Coded (Main
Uncoded Interaction Effects Interaction Effects
Effects)
Exp. # T C K T C K T×C C×K T×K T×C×K y y

9 0 0 0 50 3.5 CM 0 0 0 0 y1 60
10 0 0 0 50 3.5 CM 0 0 0 0 Y2 63
11 0 0 0 50 3.5 CM 0 0 0 0 Y3 57
Random Error
σ = ±3 ‫اجت معه بالصدفة‬ ‫خبط عشواء‬
‫شنص‬ ‫اجت معه بالقصد او بالفعل‬

54
y8
C=-5 60
y6
66.75 y7
61.75
y3
y4
y5
C- C+
y1
y2
y2 + y4 + y6 + y8
=75.75 45
4
54
C=? 68
52
60
72
C- C+
y1 + y 3 + y 5 + y 7
=52.75
4
1.5
54
y2 + y6
=77.5
C- 2
60
21.5
y1 + y 5
=56 y4 + y8
2 =74
C+ 2
y3 + y7
=49.5 24.5
2
T- T+

Term Effect
T 23.000
C -5.000
K 1.500
T*C 1.500
T*K 10.000
C*K -0.000
T*C*K 0.500

Term Effect
T 23.000
C -5.000
K 1.500
T*C 1.500
T*K 10.000
C*K -0.000
T*C*K 0.500

Explanation of Interaction Plots
Revealing T Effect by Difference
y4-y3 - y2-y1 y8-y7 - y6-y5

+
2 2 y4-y3 y2-y1 y8-y7 y6-y5
- + -
Revealing C Effect by Difference 2 2 2 2
T×C=
2 2
Hiding K Effect by Difference
“‫”من دھنه سقيله‬

45
Exp. # T C K T×C C×K T×K T×C×K y y
1 -1 -1 -1 +1 +1 +1 -1 y1 60
80
2 +1 -1 -1 -1 +1 -1 +1 Y2 72
3 -1 +1 -1 -1 -1 +1 +1 Y3 54
4 +1 +1 -1 +1 -1 -1 -1 Y4 68
54
5 -1 -1 +1 +1 -1 -1 +1 Y5 52
68
6 +1 -1 +1 -1 -1 +1 -1 Y6 83
7 -1 +1 +1 -1 +1 -1 -1 Y7 45
52
8 +1 +1 +1 +1 +1 +1 +1 y8 80 83
60
72

Explanation of Main Effects Plots
T+ =75.75
C+ = 61.75
C- = 66.75
T- = 52.75
K+ = 65
K- = 63.5
45+52+80+83 60+72+54+68
72+68+83+80 60+54+45+52 54+68+80+45 60+72+52+83 K= -
T= - C= - 4 4
4 4 4 4
C+ = 61.75 C- = 66.75 K+ = 65 K- = 63.5
T+ =75.75 T- = 52.75

Revealing T Effect by Difference
y4-y3 y2-y1 y8-y7 y6-y5

C+ C- C+ C-
- + -
2 2 y4-y3 y2-y1 y8-y7 y6-y5
- + -
Revealing C Effect by Difference 2 2 2 2
T×C= =
2 2
Hiding K Effect by Difference
C+ C+ C- C- C+ C+ C- C-
y4-y3 y8-y7 y2-y1 y6-y5 y4+y8 y3+y7 y2+y6 y1+y5
+ - - ( - )- ( - )
2 2 2 2 2 2 2 2
T×C= =
2 2
y4+y8 y4=(T+, C+,K-)

2 y8=(T+, C+, K+)
y2=(T+, C-, K-) y2+y6
C+ =
y3+y7 y3=(T-, C+, K-) y6=(T+, C-, K+) 2
2 y7=(T-, C+, K+) C-
y1=(T-, C-, K-) y1+y5
y5=(T-, C-, K+) 2
T- T+
y4+y8 y4=(T+, C+,K-)

74 =
2 y8=(T+, C+, K+)
y2=(T+, C-, K-) y2+y6
C+ = 77.5
y3+y7 y3=(T-, C+, K-) y6=(T+, C-, K+) 2
49.5 = C-
2 y7=(T-, C+, K+)
+y5
y1=(T-, C-, K-) y1+y
= 56
y5=(T-, C-, K+) 2
T- T+
y4+y8 y4=(T+, C+,K-)

74 =
2 y8=(T+, C+, K+)
T+ y3=(T-, C+, K-) y3+y7
y7=(T-, C+, K+)
= 49.5
y2+y6 y2=(T+, C-, K-) 2
77.5 = T-
2 y6=(T+, C-, K+)
y1=(T-, C-, K-) y1+y5
- - + = 56
y5=(T , C , K ) 2
C- C+

77.5 T+ 74
56
T-
49.5
y4+y8 y4=(T+, C+,K-)

74 =
2 y8=(T+, C+, K+)
T+ y3=(T-, C+, K-) y3+y7
y7=(T-, C+, K+)
= 49.5
y2+y6 y2=(T+, C-, K-) 2
77.5 = T-
2 y6=(T+, C-, K+)
y1=(T-, C-, K-) y1+y5
= 56
y5=(T-, C-, K+) 2
C- C+

45
Pilot Plant Investigation 23 Full Factorial Design Matrix
80
Exp. # T C K T×C C×K T×K T×C×K y y
1 -1 -1 -1 +1 +1 +1 -1 y1 60
2 +1 -1 -1 -1 +1 -1 +1 Y2 72 54
3 -1 +1 -1 -1 -1 +1 +1 Y3 54
4 +1 +1 -1 +1 -1 -1 -1 Y4 68
68
5 -1 -1 +1 +1 -1 -1 +1 Y5 52 52
6 +1 -1 +1 -1 -1 +1 -1 Y6 83
83
7 -1 +1 +1 -1 +1 -1 -1 Y7 45
8 +1 +1 +1 +1 +1 +1 +1 y8 80
60
y7
72
y8
y3
y4
y5
y6
y1 Pilot Plant Investigation 23 Full Factorial Cube Plot

y2
11
Dr. Mohammad A. Aliedeh
y7
23 Full Factorial Design Main
Effects Geometrical Interpretation y7
y8 y8
y3 y3
y4 y4
y5 y5
y6 y6
y1 y1
y2 y2
-y1+y2-y3+y4-y5+y6-y7+y8 y7 -y1-y2-y3-y4+y5+y6+y7+y8
A= C=
4 4
y8
y3
-y1-y2+y3+y4-y5-y6+y7+y8
B= y4
4 y5
y6
y1
y2
23Full Factorial Design Main y7
y7 Effects Geometrical Interpretation
y8
y8
y3
y3
y4
y4
y5
y5 y7 y6
y6
y8
y1
y1
y3 y2
y2
y4
y5
Revealing the effect of A
by Difference y6
y5+y6+y7+y8 y1+y2-y3+y4
y2+y4+y6+y8 y1+y3+y5+y7 y1 C= -
A= - 4 4
4 4 y2
C+ C-
A+ A-
y3+y4+y7+y8 y1+y2+y5+y6
Hiding the effect of B B= -
4 4
and C by Average
B+ B-
y7
Exp. # A B C A×B B×C A×C A×B×C y
1 -1 -1 -1 +1 +1 +1 -1 y1 y3
2 +1 -1 -1 -1 +1 -1 +1 Y2
y4
3 -1 +1 -1 -1 -1 +1 +1 Y3
y5
4 +1 +1 -1 +1 -1 -1 -1 Y4
5 -1 -1 +1 +1 -1 -1 +1 Y5 y6
6 +1 -1 +1 -1 -1 +1 -1 Y6
y1
7 -1 +1 +1 -1 +1 -1 -1 Y7
8 +1 +1 +1 +1 +1 +1 +1 y8 y2

Typical 23 Full Factorial Design Cube Plot
y2-y1 + y4-y3 + y6-y5 + y8-y7
A=
4 y1-y2-y3+y4+y5-y6-y7+y8
A×B= B×A=
Hiding B and C Effect by Difference 4
Revealing B Effect by Difference

y3-y1 + y4-y2 + y7-y5 + y8-y6

B= y5-y1 + y6-y2 + y7-y3 + y8-y4
4 C=
Hiding A and C Effect by Difference
4
Hiding A and B Effect by Difference
y7
y8
y3
y2-y1 + y4-y3 + y6-y5 + y8-y7
A= y4
4 y5
Hiding B and C Effect by Difference y6
y1
y2
y3-y1 + y4-y2 + y7-y5 + y8-y6
B=
4
-y1+y2-y3+y4-y5+y6-y7+y8
Hiding A and C Effect by Difference A=
4
-y1-y2+y3+y4-y5-y6+y7+y8
B=
y5-y1 y6-y2 y7-y3 y8-y4
4
+ + +
C=
4 -y1-y2-y3-y4+y5+y6+y7+y8
Hiding A and B Effect by Difference C=
4

y7
y8
y4-y3 - y2-y1 y8-y7 - y6-y5
+
y3
2 2
y4
A×B= y5
2 y6
Hiding C Effect by Difference
y1
Revealing B Effect by Difference y2
y4-y2 - y3-y1 y8-y6 - y7-y5

+
2 2
B×A=
2
Hiding C Effect by Difference
y1-y2-y3+y4+y5-y6-y7+y8
A×B= B×A=
4

y7
y8-y6 - y4-y2 y7-y5 - y3-y1

+ y3
2 2 y4
Revealing C Effect by Difference y5
B×C= y6
2
y1
Hiding A Effect by Difference
y2
Revealing C Effect by Difference
y8-y4 - y6-y2 y7-y3 - y5-y1

+
2 2
C×B=
2
Hiding A Effect by Difference
y1+y2-y3-y4-y5-y6+y7+y8
C×B= B×C=
4

y7
Revealing A Effect by Difference y8
y8-y7 - y4-y3 y6-y5 - y2-y1

+ y3
2 2 y4
Revealing C Effect by Difference y5
A×C= y6
2
Hiding B Effect by Average y1
y2
Revealing C Effect by Difference
y8-y4 - y7-y3 y6-y2 - y5-y1

+
2 2
C×A=
2
Hiding B Effect by Average
Y1-y2+y3-y4-y5+y6-y7+y8
C×A= A×C=
4

y7
y8
y3
y4-y3 - y2-y1 y8-y7 - y6-y5
+ y4
2 2 y5
A×B=
2 y1
Hiding C Effect by Difference y2
Revealing A Effect by Difference Revealing A Effect by Difference
y8-y7 y4-y3 y6-y5 y2-y1 y8-y7 - y4-y3 y6-y5 - y2-y1

- + - +
2 2 2 2
Revealing C Effect by Difference Revealing C Effect by Difference
A×C= B×C=
2 2
Hiding B Effect by Difference Hiding B Effect by Difference

23 Full Factorial Design Cube Plot
y7
7
y8
8
y3
3
y4
4 y5
5 y6
6
y1
1
y2
2

y7
y7 T×K
y8
y8
y3
y3 y4
y4 y5
y5
y6
y6
y1
y1
y2
y2
y7
y8
y3
y4
y5
y6
y1
y2
Homework (3): Study the following 8 Different Interaction Patterns, comment on them and arrange
them in the order of increasing interaction and explain the concept of interaction and your reasoning
(a) (b) A×
×B (c) A×
×B
A×
×B
B+ B+
B+
y y
y
B-
B- B-
A- A+ A- A+
A- A+
(d) (e) (f) A×

×B
A×
A ×B A×
×B
B+ B+
B+
y y
y
B- B-
B-
A- A+ A- A+
A- A+
Scatter in Data
‫فساتين كلوش‬ True Value
True Value

X X
Scatter

σ True Value
Scatter

!!!!!!!! ‫سيغما ھو الكلوش‬
X ± σ
Scatter in Data
‫فم التمساح‬ True Value

X
Scatter

σ
True Value
Scatter

X ± σ
‫ميزان الحديد‬
‫ميزان الخضار‬
Medical Scale
‫ميزان الذھب‬
True Value
Scatter

X ± σ
Generic 24 Full Factorial Design Matrix
A×B×C×D
A×B×D
A×C×D
B×C×D
A×B×C
Exp.
A×D
B×D
C×D
A×B
A×C
B×C
A B C D y
#
1 -1 -1 -1 -1 +1 +1 +1 -1 y1
2 +1 -1 -1 -1 -1 +1 -1 +1 Y2
3 -1 +1 -1 -1 -1 -1 +1 +1 Y3
4 +1 +1 -1 -1 +1 -1 -1 -1 Y4
5 -1 -1 +1 -1 +1 -1 -1 +1 Y5
6 +1 -1 +1 -1 -1 -1 +1 -1 Y6
7 -1 +1 +1 -1 -1 +1 -1 -1 Y7
8 +1 +1 +1 -1 +1 +1 +1 +1 y8
9 y9
10 Y10
11 Y11
12 Y12
13 Y13
14 Y14
15 Y15
16 y16
Dr. Mohammad A. Aliedeh

HW 4 Full Factorial Design 1/2
A research expansion with another factor has been done in the previous example. Hence, the effects of these factors
have been analyzed in this research:
21
HW 4 Full Factorial Design 2/2
You are required to do the following calculations and plotting :
A- Minitab 16 Calculations and Plots (Install the Software using the link given)
1- Main effects (A, B, C, D)
https://1drv.ms/u/s!At3zt4TyCxhEjVbLl1Bf0zjdGB4o?e=qHaoc2
2- Interaction Effect (all of them)
3- Main Effect Plots (A, B, C, D)
4- Two Interaction effect plots (A*B, A*C, A*D, C*D, ……..)
5- Short video showing how you used the Minitab software
B- Hand Calculations and Plots

1- Main effects (A, B, C, D) and Plots + Graphical and Formula Explanation
2- Interaction Effect (A*B, A*C, A*D, C*D) and Plot+ Graphical and Formula Explanation
3- Short video describing verbally your previous explanations for just two of them.

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Exam Seat Position Course Oglah Falhan

First Closely Seated Mass Transfer 75 92

Second Closely Seated Mass Transfer 82 85

First Front Seated Mass Transfer 27 87

Second Front Seated Heat Transfer 22 86

Estimated Effects and Coefficients for Oglah (coded units)

Term Effect Coef

Estimated Effects and Coefficients for Falhan (coded units)

Term Effect Coef

3 Understanding Key Interactions in Processes 3

3.2 Alternative Method for 3.3 Synergistic

Interactions Main Effects

(a) (b) (c)

(d) (e) (f)

Box, G. E. P., Hunter J. S., and Hunter

Generic 22 Full Factorial Design Matrix y3

Exp. # A B A×B y y3 y4-y3 y4 y4

Effects Explanations Short Cut Method

Revealing A Effect by Difference Revealing B Effect by Difference

y4-y2 - y3-y1 y4-y3 - y2-y1 y1-y2-y3+y4

Generic 22 Full Factorial Design Matrix y3

Effects Explanations Short Cut Method

Revealing A Effect by Difference Revealing B Effect by Difference

y4-y2 - y3-y1 y4-y3 - y2-y1

A Main Effect Plot

Main Effect Plot

y2 Revealing A Effect by Difference

Pilot Plant Performance Experiments

Exp. # T C K T C K T×C C×K T×K T×C×K y y

Dr. Mohammad A. Aliedeh σ= ± 3 02

Exp. # T C K T C K T×C C×K T×K T×C×K y y

‫شنص‬ ‫اجت معه بالقصد او بالفعل‬

Pilot Plant Performance Experiments

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Dr. Mohammad A. Aliedeh 04

Revealing T Effect by Difference

y4-y3 - y2-y1 y8-y7 - y6-y5

“‫”من دھنه سقيله‬

Dr. Mohammad A. Aliedeh 06

Explanation of Main Effects Plots

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y4-y3 y2-y1 y8-y7 y6-y5

y4+y8 y4=(T+, C+,K-)

y4+y8 y4=(T+, C+,K-)

y4+y8 y4=(T+, C+,K-)

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y4+y8 y4=(T+, C+,K-)

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y1 Pilot Plant Investigation 23 Full Factorial Cube Plot

Revealing A Effect by Difference

Revealing B Effect by Difference

y3-y1 + y4-y2 + y7-y5 + y8-y6

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Revealing B Effect by Difference y2

y4-y2 - y3-y1 y8-y6 - y7-y5

Dr. Mohammad A. Aliedeh 16