Engineering

CSUN Management
Six Sigma Quality
Engineering

Week 11
Improve Phase
 Objectives

 Overview of Design of Experiments

• A structured method to learn about a process by changing many
factors at the same time.
• It occurs in Improvement Phase.
• Fractional factorial experiments are used for initial screening
• Full factorial experiments are smaller and more precise
 Graphical Analysis
• Main effects plots
• Interaction plots
• Cube plots
 Statistical Analysis
• P value for main effects and interactions
Six Sigma - DMAIC Roadmap
 Improve Phase

Goal:
 Develop, try out, and implement solutions that
address root causes
Improve
Develop, try out &
implement Establish Prepare
Select
solutions that Optimum improvement
Solutions
address root Process Plans
causes
 Improvement  FMEA for  Document ‘To Be’
Strategies Solution Process
 Screen Critical  Cost Benefit  Pilot Solution
Inputs (DOE Plan) Analysis
 Implementation &
 Refine Model Verify Deployment Plans
 Key Deliverables
Metrics
 Solutions Define & Confirm  Process
Y = f (x) Prioritization Documentation
 Risk Assessment on
Matrix
Solution
 Pilot Results Output:
 Implementation Plans  Planned, tested actions that eliminate or reduce
the impact of the identified root causes
 Improve Phase

Generating Solutions
Cost-Benefit Analysis
A 4
Design of Experiments
B 1
C 3
D 2
Perform cost-benefit
analysis for the
preferred solution Generate solutions including
Benchmarking and select
best approach based on Use DOE and response
screening criteria surface optimization to
quantify relationships.

Selecting the Solution

Implementation
Piloting
1 2 3 4 5 6 7 8 9 10
Assessing Risks Test
Full scale A
B
Original C
D
G
E F
G
Recommend a solution H I J
involving key
stakeholders.
Develop & Execute a full plan
for implementation and
Use FMEA to identify change management
risks associated with the Pilot the solution on
solution and take a small scale and
preventive actions evaluate the results
 Engineering
CSUN Management

Design of Experiments
 What is a Designed Experiment?

 A method to change all the factors at once in a structured

pattern to determine their effects on the output(s)
 The structured pattern is known as an orthogonal array

A B AXB
1 -1 -1 1
2 1 -1 -1
3 -1 1 -1
4 1 1 1
0 0 0
 Full Factorial Designs

 Full Factorial: Examines factor effects and interaction effects.

These become large rather quickly.

• 22 Full Factorial = 2 factors, 2 levels = 4 runs

• 23 Full Factorial = 3 factors, 2 levels = 8 runs
• 24 Full Factorial = 4 factors, 2 levels = 16 runs
• 25 Full Factorial = 5 factors, 2 levels = 32 runs

 Used after initial screening experiments or where the process

is simple or well known. The experiment is run to optimize
the process using a vital few factors.
 Example of a 23 Full Factorial Design

Run s
Yate
Order A B AxB C AxC BxC AxBxC
1 -1 -1 1 -1 1 1 -1
2 1 -1 -1 -1 -1 1 1
3 -1 1 -1 -1 1 -1 1
4 1 1 1 -1 -1 -1 -1
5 -1 -1 1 1 -1 -1 1
6 1 -1 -1 1 1 -1 -1
7 -1 1 -1 1 -1 1 -1
8 1 1 1 1 1 1 1
 Fractional Factorial Designs

 Fractional Factorial: Examines factor effects and a carefully

selected portion of interaction effects.

 Shrinks the number of runs for each fraction by one half.

• 27 Full Factorial = 7 factors, 2 levels = 128 runs

• 2(7-1) 1/2 Fractional Factorial = 7 factors, 2 levels = 64 runs
• 2(7-2) 1/4 Fractional Factorial = 7 factors, 2 levels = 32 runs
• 2(7-3) 1/8 Fractional Factorial = 7 factors, 2 levels = 16 runs
• 2(7-4) 1/16 Fractional Factorial = 7 factors, 2 levels = 8 runs
 Fractional Factorial Designs

 Uses interaction column settings to estimate the effects of

main factors.
 Used for initial screening designs to isolate the important
(vital few) factors.
 One DoE leads to another. Fractional Factorial DoE’s lead to
smaller Full Factorial DoE’s.
Basic Experimental Terms
 The Idea of Confounding

A B C AB AC BC ABC
2 (a) 1 -1 - -1 -1 1 1
1
3 (b) -1 1 -1 1 -1 1
-
5 (c) -1 -1 1 -1 -1 1
1
8 (abc) 1 1 1 1 1 1
1
1 Signs
Same

Was “Y” affected by A or by the interaction of B and C?

Basic Experimental Terms
Basic Experimental Terms
Basic Experimental Terms
 General Comments

 In general, industry considers 3rd and 4th order interactions

to be negligible.
 Fractional Factorial experiments “pool” the effects of
interactions to estimate residual error.
 No replicates are run - USE WITH CAUTION!
 Use Fractional Factorial Experiments for screening, then
follow up with Full Factorial Designs.
 Keep your experiments simple
 Be Proactive!

 DOE is a proactive tool.

 If DoE output is inconclusive:
• You may be working with the wrong variables
• Your measurement system may not be capable
• The range between high and low levels may be insufficient
 There is no such thing as a failed experiment
• Something is always learned
• New data prompts asking new questions and
generates follow-on studies
 Engineering
CSUN Management

Design of Experiments
Minitab practice
 Design Resolution

The resolution number tells you what factor and

interactions will be confounded with one another.
Questions? Comments?