Lean Six Sigma Green Belt

Certification Course
Design of Experiments
 Learning Objectives

By the end of this lesson, you will be able to:

Explain the concept of Design of Experiments (DOE)

Compare DOE with regression analysis

Identify the meaning of the basic terms used when

conducting experiments

Explain the effects of DOE error on repetition, replication,

randomization, and blocking
 Introduction

The problem

Pre-ground coffee?

Milk?
Added flavors?

Temperature?
Serving size?

JAVA HOUSE COFFEE

 Introduction

The solution

Freshly ground
coffee
115 ml milk
5 ml flavoring

60–65⁰C
Serving size 120 ml

JAVA HOUSE COFFEE

Design of Experiments (DOE)
 Design of Experiments (DOE)

Input variables Process Output variable

Uncontrollable input
variables
 Design of Experiments (DOE)

Is a one-stop method for analyzing all influencing factors simultaneously

Used when known sources of variation have been eliminated but process is
still not capable; if process is capable then DOE may not be required

DOE Identifies which variables individually affect key measures

Determines variable combinations or interactions that impact capability

Provides mathematical model to predict and optimize the response or process

output under recommended settings

Is preferred over One Factor at a Time (OFAT) experiments because it allows

for accelerated learning and is less time-consuming
 Regression Analysis

Regression analysis generates a line on a scatter plot that quantifies the relationship between X and
Y to understand variation impact.

High percentage of variability in • Predict future values of Y given X and X given Y

Changes in X
Y (R2> 70%)
• Regress Y on one or more Xs simultaneously
 DOE vs. Regression Analysis

DOE Regression

• Determines cause and effect • Uncovers relationships

• Tries bold or creative solutions • Uses existing data

• Clears results on the impact variable • Results left open to interpretation

• Measures impact on variability • Cannot measure variability impact

• Provides reliable information on interactions • Provides risky information on interactions

• Requires leadership support and investment • Does not require leadership support
Basic Terms

Response

Factors

Levels

Interactions

Treatment

Trial

Experimental unit
 Basic Terms

Response

Factors
• Dependent variables or outcomes of an experimental treatment that
Levels varies as changes are made to factors

Interactions

Examples:
Treatment
Product strength, average hold time, sales, response time
Trial

Experimental unit
 Basic Terms

Response

Factors
• Independent or input variables that are changed during an experiment
Levels to validate their impact on the output
• Can be qualitative and/or quantitative
Interactions

Treatment Examples:
Machine, temperature, procedural change, price
Trial

Experimental unit
 Basic Terms

Response Objective: To achieve uniform dimensions for a part at a particular target

value
Factors
Inputs (X) Process Output (Y)
Levels

Interactions Cycle time

Mold temperature
Holding pressure Molding Part hardness
Treatment Holding time
Material type
Trial

Experimental unit Factors Response

 Basic Terms

Response

Factors • Settings or conditions of the factors that are tested during the
experiment
Levels • Two levels recommended per factor
• Level 1 is normally coded as “-” and could represent status quo
Interactions • Level 2 is normally coded as “+” and could represent the change
tested
Treatment

Trial Note: The difference between level 1 and level 2 settings should be
significant to detect impact.
Experimental unit
 Basic Terms

Response DOE conducted on two factors at two levels to determine the impact
related to plastic part hardness
Factors

Levels Level
Factors
- +
Interactions
Quantitative factor Mold temperature 700° 900°
Treatment

Trial Qualitative factor Plastic type Filler No filler

Experimental unit
 Basic Terms

Response

Factors

• When the combination of two factors creates a result that is different

Levels from the result produced by the individual factors

Interactions
Examples:
Treatment Baking time and temperature

Trial

Experimental unit
 Basic Terms

Response

Factors

Levels • A unique set of factors at specific levels whose effect on the response
variable is of interest
Interactions
Examples:
Molding temperature at high setting and baking time at low setting
Treatment

Trial

Experimental unit
 Basic Terms

Response

Factors

Levels
• An experimental run for a specific treatment
Interactions

Treatment

Trial

Experimental unit
 Basic Terms

Response

Factors

Levels

Interactions • Quantity of material to which one trial of a single treatment is applied

to create a response
Treatment

Trial

Experimental unit
 DOE Error

Error is variation in experimental units that have been exposed to the same treatment.

Examples:
Humidity | Season | Geographic location | Shift
 Repetition and Replication

Repetition Replication

The entire experiment is

During a treatment setup, several
repeated with a change in the
samples are run without
setting of experimental
changing the setting.
conditions between trials.

This shows short-term variability. This shows long-term variability.

Repetition and replication provide an estimate of experimental error and help determine the
statistical significance of the differences in readings.
 Error and Randomization and Blocking

• Running the trial without any order

• The use of randomization helps • Setting the DOE so that controllable

with: noise factors are incorporated into the
• Noise factors that are experiment or held at a constant level
completely random and throughout
uncontrollable
• Avoiding time-related changes,
uncontrollable variables, and
tool wear
• Eliminating bias in expert
opinions

Randomization Blocking
 Full Factorial Experiment

● Contains all combinations of all levels of all

factors

● Ensures no possible treatment combinations get

Full factorial experimental design
omitted

● Is preferred over other designs

 Full Factorial Experiment

Factor B: Factor A:
EXAMPLE Oven Time (X2) Draw Temperature (X1)

700 °F 900 °F

Y1 Y5
30 minutes
Y2 Y6

Y3 Y7
60 minutes
Y4 Y8 The tables depict a
two-way heat
treatment experiment,
Factor A = Temp: Low (-) 700 ⁰F; High (+) 900 ⁰F where Y is the Part
Responses
Factor B = Time: Low (-) 30 minutes; High (+) 60 minutes hardness.
Trial DOE Order A B AB 1 2
1 3 - - + Y1 Y2
2 1 + - - Y3 Y4
3 4 - + - Y5 Y6
4 2 + + + Y7 Y8
 Full Factorial Experiment

Main Effect is the average response change going from one setting to the other.

Factor A:
Factor B:
Draw Temperature An analysis of the response helps in understanding how:
Oven Time (X2)
(X1)

700° 900°
A change in A change in oven time Interaction between
temperature at which creates a difference in temperature and time
Y1 Y5 the average part affects the average part
30 minutes the material is drawn
Y2 Y6 hardness hardness
creates a difference in
Y3 Y7 the average part
60 minutes hardness
Y4 Y8
 Full Factorial Experiment

Factor B: Factor A:
Oven Time Draw Temperature

A1 = 700° A2 = 900°

B1 = 30 90 84
minutes 87 87

B2 = 60 95 79
minutes 92 78

Results: Results:
The table depicts a two-way heat Changing the draw temperature seems to Changing the oven time seems to
treatment experiment. change the average hardness have no major change in the average
hardness
 Full Factorial Experiment

95

Part Hardness
Factor B: Factor A:
Oven Time Draw Temperature
90 700
A1 = 700° A2 = 900°
85
B1 = 30 90 84
minutes 87 87
900
95 79 80
B2 = 60
minutes 92 78
30 min. 60 min.

A1 A2
Results: The interaction plot shows that low
B1 88.5 85.5 temperature and high oven time should be selected
90+87 to achieve the highest desired output of hardness.
A,B, = = 88.5
B2 93.5 78.5 The parallel lines indicate the output if no
2
interactions occur between the main effects.
The mean of the factors

28
 Runs

The number of experiments in a DOE setting is known as Runs.

Full Factorial Runs = Levels^factors

The number of runs in a:

Half Fractional Factorial Runs = Levels^(factors-1)

 Runs

For Half Fractional factorial experiments, the number of runs is levels to the power of factors minus 1.

Full factorial experiment without replication on 5 factors and 2 levels: 25 = 32

Full factorial experiment with 1 replication on 5 factors and 2 levels: 32 + 32 = 64
Half fractional factorial experiment without replication on 5 factors 25-1 = 16
and 2 levels:
Half fractional factorial experiment with 1 replication on 5 factors 16 + 16 = 32
and 2 levels:

Fractional factorial experiments lose complete information on interactions.

 Fun Facts

DID YOU
KNOW…?

The use of DOE is growing in the service

sector.
 Key Takeaways

DOE is a structured method that tests input variables and their

impact on the output variable.

Error is variation in experimental units that have been

exposed to the same treatment.

Repetition and replication provide an estimate of

experimental error and help determine the statistical
significance of the differences in readings

Randomization and Blocking can impact the effects of error.

Full factorial experimental design contains all

combinations of all levels of all factors.

The number of experiments in a DOE setting is known as Runs.

Knowledge Check
Knowledge
Check A chef wants to change the recipe for a fondue to improve its taste. He is considering
1 different cheeses and will run 8 experiments. In this scenario, what is the factor?

A. Experiments

B. Fondue

C. Different cheeses

D. Taste
 Knowledge
Check A chef wants to change the recipe for a fondue to improve its taste. He is considering
1 different cheeses and will run 8 experiments. In this scenario, what is the factor?

A. Experiments

B. Fondue

C. Different cheeses

D. Taste

The correct answer is C

The factor is the independent variable that is changed and in this case it will be the different cheeses.
Knowledge
Check A chef wants to change the recipe for a fondue to improve its taste. He is considering
2 different cheeses and will run 8 experiments. In this scenario, what is the response?

A. Experiments

B. Fondue

C. Different cheeses

D. Taste
 Knowledge
Check A chef wants to change the recipe for a fondue to improve its taste. He is considering
2 different cheeses and will run 8 experiments. In this scenario, what is the response?

A. Experiments

B. Fondue

C. Different cheeses

D. Taste

The correct answer is D

The response is the dependent variable that is impacted by changing factors and in this case it will be the taste.
Knowledge
Check For a full factorial experiment with 3 factors at two levels that are replicated twice,
3 how are trials expected?

A. 24

B. 8

C. 16

D. 9
 Knowledge
Check For a full factorial experiment with 3 factors at two levels that are replicated twice,
3 how are trials expected?

A. 24

B. 8

C. 16

D. 9

The correct answer is A

The equation is levels to the power of factors. 2 to the power of 3 is 8 and with two replications would be 8 + 8 + 8 = 24.