Two-Level Factorial Designs

Presented by:
Juanito S. Chan, PIE
 Standard 23 Design
Where do the factors
Run A B C (independent variables)
1 -1 -1 -1 appear in this table?
2 +1 -1 -1 Where do the responses
(dependent variable)
3 -1 +1 -1
appear in this table?
4 +1 +1 -1 What do the 1 and +1
5 -1 -1 +1 mean?
6 +1 -1 +1 Should these
7 -1 +1 +1 experimental runs be
made in the order they
8 +1 +1 +1 are shown?
 Standard 23 Design
Factors are A, B, C
Run A B C Responses do not appear in
this table?
1 -1 -1 -1
Choose a high and a low
2 +1 -1 -1 value for each factor.
3 -1 +1 -1 o -1 means set factor to low
level in this run
4 +1 +1 -1 o +1 means set factor to high
level in this run
5 -1 -1 +1 Run order should be
6 +1 -1 +1 randomized
o Failure to randomize very
7 -1 +1 +1 risky for factor C, since it has
8 +1 +1 +1 runs 1-4 at low level and 5-8
at high level
Maximize Reaction Yield
2 Factorial Design
3

Objective: maximize reaction yield

Factors:
o A = catalyst weight percent (1,2)
o B = reaction time, hours (1,2)
o C = temperature, F (200,250)
Response: Reaction yield, %
 Maximize Reaction Yield
Run Catalyst Reaction Temperature, Yield, %
Weight % Time, hr F
1 1 1 200 65.3
2 2 1 200 81.3
3 1 2 200 53.3
4 2 2 200 69.9
5 1 1 250 61.8
6 2 1 250 77.4
7 1 2 250 73.9
8 2 2 250 89.9
 Now What?
Calculate effects of each factor and interaction
Decide which effects are important
Plan another, multilevel experiment focusing
on the important variables
 Interactions
-1 -1 = +1

Run A B C AB AC BC ABC Y
1 -1 -1 -1 +1 +1 +1 -1 65.3
2 +1 -1 -1 -1 -1 +1 +1 81.3
3 -1 +1 -1 53.3
4 +1 +1 -1 69.9
5 -1 -1 +1 61.8
6 +1 -1 +1 77.4
7 -1 +1 +1 73.9
8 +1 +1 +1 89.9
Note that each factor is tested at each level 4 times.
Investigating Interactions

You set the value for each factor in each

experiment
The interactions happen naturally
o You do not set some level of AB interaction; it
happens automatically because of the levels
you set for A and B individually
Interactions are a physical reality of the
system, and will happen whether you
calculate an effect for them or not
How to Calculate Effects
High Total = sum of all response values
when the factor is at the +1 level
Low Total = sum of all response values
when the factor is at the 1 level
Difference = (High Total) (Low Total)
o Note that you can also calculate the difference
by multiplying each +1 or 1 by the response
for its row, then summing all the values in the
column. That is what your book says.
Effect = Difference / (# runs at each level)
 Effects
A B C AB AC BC ABC
Cat. Wgt. % Rxn Time Temp

High
Total
Low
Total
Diff

Effect
On Y
 Effects
A B C AB AC BC ABC
Cat. Wgt. % Rxn Time Temp

High 318.5 287.0 303.0 286.9 285.9 310.4 286.3

Total
Low 254.3 285.8 269.8 285.9 286.9 262.4 286.5
Total
Diff 64.2 1.2 33.2 1.0 -1.0 48.0 -0.2

Effect 16.05 .30 8.30 0.25 -0.25 12.00 -0.05

On Y
 Scree Plot to Identify Order of
Importance
18
16
14
Effect on Reaction Yield

12
10
8
6
4
2
0
-2 A BC C B AB AC

Factor
Conclusions

Increasing catalyst weight % or increasing

temperature will increase the yield
o Increasing catalyst is most effective
Increasing reaction time itself has little
effect on yield, but in combination with
increased temperature multiplies the effect
of temperature
 Comparison with OFAT
OFAT would reveal the effect of catalyst and
temperature.
OFAT would not reveal the time-temperature
interaction.
OFAT would not reveal the lack of time-
catalyst and temperature-catalyst interaction.
 Adding a Factor
Adding a factor to a full factorial design doubles
the number of experimental runs
o 3 factors = 23 = 8 runs
o 4 factors = 24 = 16 runs
If you are confident that an interaction is
unimportant, you can substitute a new factor for
that interaction term in the test matrix
o 3-way interaction least likely to be important
o Substitution of a factor for an interaction makes an
unsaturated design
 Unsaturated Designs and Aliasing
If a factor replaces an interaction in the design,
o You cannot tell the difference between the effect of the
factor and the effect of the interaction
o Interaction is an innate property of the system. You do not
control whether or not it happens by deciding whether or not
to study it.
o Some or all of the effect you calculate for the new factor
could be due to the interaction between other factors.
o You cannot study how the new factor interacts with
others