6/1/2012

MEE604

MEE604
60 Design
D i and
dA
Analysis
l i off Experiments
i
M.Tech.(CAD/CAM) and M.Tech.(Manufacturing), Summer2011-12, Slot:D
Lecture 1 : Syllabus, (Unit I) Introduction to DOE

Professor,ManufacturingDivision,
SchoolofMechanicalandBuildingSciences,
VITUniversity,Vellore 632014,India.
akjeevanantham@vit.ac.in
akjeevanantham@yahoo.com

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment
Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Introduction (What is DOE)

Design:
The process of creating and developing a plan for a
product, structure, system, or component with intention

Experiment:
The test or series of tests in which a purposeful changes
are made to the input variables of a process or a system
so that we may observe or identify the reason for
changes that may be observed in the output response.
The purpose of an experiment: to reveal the response of
one variable to changes
g in other variables.

Applications
of
Applicationsof
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Dr.A.K.Jeevanantham, M.E.,Ph.D.,

MEE604

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Design and Analysis of Experiments

General model of a Process or System

MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Overview

Applications
of
Applicationsof
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Design and Analysis of Experiments

Design and Analysis of Experiments

Introduction (What is DOE)

The objectives of the experiment may include the
following:
1 Determining which variables are most influential on the
1.
response y
2. Determining where to set the influential x's so that y is
almost always near the desired nominal value
3. Determining where to set the influential x's so that variability
in y is small.
4. Determining where to set the influential x's so that the
effects of the uncontrollable variables z1, z2, z3, zq are
minimized.

General model of a Process or System

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MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

A metallurgical engineer is interested in studying the effect

of two different hardening processes, oil quenching and
saltwater quenching, on Al alloy.
Objective of the experimenter:
to determine which quenching solution produces the
maximum hardness for this particular alloy.
1. Are these two solutions the only quenching media of potential
interest?
2. Are there any other factors that might affect hardness that
should be investigated or controlled in this experiment?
3. How many coupons of alloy should be tested in each quenching
solution?
4. How should the test coupons be assigned to the quenching
solutions, and in what order should the data be collected?
5. What method of data analysis should be used?
6. What difference in average observed hardness between the
two quenching media will be considered important?
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MEE604

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

MEE604

Introduction (Example)

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Design and Analysis of Experiments

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Syllabus
Unit 4:

Syllabus

Unit 5: Orthogonal Experiments

Selection and application of orthogonal arrays for
design, Conduct of experiments, collection of data
and analysis of simple experiments, Modifying
orthogonal arrays, Inner and outer OA experiments,
Optimization using S/N ratios, attribute data analysis,
a critique of robust design.

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Unit 1: Introduction
Basic principle of DOEs, Guide lines for Designing
Experiments, Terminology, ANOVA, Computation of
sum of squares and Basics of quality by design.

Unit 2: Single Factor Experiments

Randomized complete block design, Latin square
design, GraecoLatin square design, incomplete block
design and Tests on means.

Unit 3: Factorial Design

TwoFactor factorial design, General factorial design,
2k Factorial design, 3k Factorial design, confounding,
Fractional replication and Factors with mixed levels.
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Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment
Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Robust Design Process

Comparison of classical and Taguchi

Taguchiss approach,
variability due to noise factors, principle of
robustization, classification of quality characteristics
and parameters, objective functions in robust design,
S/N ratios.

MEE604

Design and Analysis of Experiments

Design and Analysis of Experiments

Design and Analysis of Experiments

Reference books
Philip J. Rose, Taguchi Techniques for Quality
Engineering, Prentice Hall, 1989.
Douglas C. Montgomery, Design and Analysis of
Experiments, John Wiley and Sons, 8th Edition,
2012.
Nicolo Belavendram, Quality by Design: Taguchi
Techniques for Industrial Experimentation,
Prentice Hall,
Hall 1995

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MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

MEE604

Mode of Evaluation
Internal Assessment:

(50 Marks)

Quiz (5Questions 1mark)

Quiz 1

5 Marks

Quiz 2

5 Marks

Quiz 3

5 Marks

Assignment
5 Marks
Continuous Assessment Test
(Part A: 1Question 10marks = 10marks
Part B: 2Question 20marks = 40marks)

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

CAT1
CAT2

15 Marks
15 Marks

External Assessment:

(100 Marks)

Term End Examination

(5Questions 20marks = 100marks)
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MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment
Applications of
Applicationsof
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Design and Analysis of Experiments

Reducetime todesign/develop
newproducts&processes
d t &
Improveperformance of
existingprocesses
Improvereliability and
performanceofproducts
Achieveproduct&process
robustness
Evaluation ofmaterials,design
alternatives,setting
component&system
tolerances,etc.

Strategy of Experimentation
The general approach to planning and conducting the
experiment is called the strategy of experimentation.

Bestguess experiments
Used a lot
More successful than you might suspect, but there are
disadvantages

Onefactoratatime (OFAT) experiments

Sometimes associated with the scientific or engineering
method
Devastated by interaction,
interaction also very inefficient

Statistically designed experiments

Based on Fishers factorial concept

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MEE604

Design and Analysis of Experiments

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Engineering Experiment

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment
Applications of
Applicationsof
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

General model of a Process or System

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Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Design and Analysis of Experiments

Design and Analysis of Experiments

Applications of Experimental Design

in process development
1. Improved process yields
2. Reduced variability and closer conformance to nominal or
target requirements
3. Reduced development time
4. Reduced overall costs

in engineering design
1. Evaluation and comparison of basic design configurations
2. Evaluation of material alternatives
3. Selection of design parameters so that the product will work
well under a wide variety of field conditions,
conditions that is,
is so that
the product is robust
4. Determination of key product design parameters that impact
product performance

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MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Design and Analysis of Experiments

1. Randomization
2 Replication
2.
3. Blocking

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MEE604

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

The Basic Principles of DOE

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

MEE604

Design and Analysis of Experiments

The Basic Principles of DOE

2. Replication
repetition of the basic experiment.
Important properties:
1. it allows the experimenter to obtain an estimate of
the experimental error. This estimate of error
becomes a basic unit of measurement for
determining whether observed differences in the
data are really statistically different.
2. Second, if the sample mean (e.g., y) is used to
estimate the effect of a factor in the experiment,
replication permits the experimenter to obtain a
more precise estimate of this effect.

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

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MEE604

The Basic Principles of DOE

1. Randomization
both the allocation of the experimental material and the
order in which the individual runs or trials of the
experiment are to be performed are randomly
determined.
Running the trials in an experiment in random order in
which the individual runs or trials of the experiment are
to be performed are randomly determined.
Statistical methods require that the observations (or
errors) be independently distributed random variables.
[Randomization usually makes this assumption valid].

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Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment
Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

Design and Analysis of Experiments

Design and Analysis of Experiments

The Basic Principles of DOE

3. Blocking
a design technique used to improve the precision with
which comparisons among the factors of interest are
made.
Often blocking is used to reduce or eliminate the
variability transmitted from nuisance factors; that is,
factors that may influence the experimental response
but in which we are not directly interested.

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6/1/2012

MEE604
Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Design and Analysis of Experiments

MEE604

Guidelines for Designing Experiments

Pre-experimental planning

1.

Recognition of and statement of the problem.

2.

Choice of factors, levels and ranges.

Potential design factor design / heldconstant / allowed to vary factors
Nuisance factor controllable / uncontrollable / noise factors

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

3.

Selection of the response variable.

4.

Choice of experimental design.

5.

Performing the experiment.

6.

Statistical analysis of the data.

7.

Conclusions and recommentations.

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MEE604

Design and Analysis of Experiments

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Terminologies

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

(p
| |) Measureoferror,effect,orinteractionby
,
,
y
ttest(prob>|t|)
seeingifprob>|t|issignificantinat
distribution(>95or99%).

Terminologies

Definition

Blocking

Methodtoseparatealengthyorimmobileseriesof
experimentswithoutlosingstatisticalanalysis

ANOVA

AnalysisofVariancemethodtostatistically
analyzetheresultsofanexperimentusingt
testorothermethods

Randomization

Allowsforerroranalysis:inoperator,
equipment,experimentdesign,etc

Factor
interaction

Whentwofactorsarecertainlevelscausea
significantchangeinresponsetogether
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Design and Analysis of Experiments

Introduction
Syllabus
Reference
Books
Modeof
Evaluation
Engineering
Experiment
Strategiesof
Experiment

Terminologies

Applicationsof
Applications
of
DOE
Principlesof
DOE
Guidelinesfor
DOE
Terminologies

OFAT

Onefactoratatimemethodofresearch

BestGuess

Attempttorunexperimentatabestguess

Residues

Enabletodeterminemodeladequacy

Terminologies

Definition

Factorial
experiment

2nexperimentwherenfactorsarevariedwith
respecttooneanother

Factor

avariableinanexperimentthatmayeffectthe
systemunderstudy

Response

theoutputunderstudy

Level

Upperorlowerlimitofafactor

Replication

Numberoftimesanexperimentisrepeated

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