Industrial Engineering

23 Factorial Design

Introduction

Suppose that three factors, A, B, and C, each at two levels, are of interest. The design is called a 23 factorial design and the eight treatment combinations can now be displayed geometrically as a cube.

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

There are seven degrees of freedom between the eight treatment combinations in the 23 design. Three degrees of freedom are associated with the main effects of A, B, and C. Four degrees of freedom are associated with interactions; one each with AB, AC, and BC and one with ABC.

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

Sums of squares for the effects are easily computed, because each effect has a corresponding single-degree-of-freedom contrast. In the 23 design with n replicates, the sum of squares for any effect is

23 Factorial Design

Algebraic Signs for Calculating Effects in the 23 Design

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

A soft drink bottler is interested in obtaining more uniform fill heights in the bottles produced by his manufacturing process. The filling machine theoretically fills each bottle to the correct target height, but in practice, there is variation around this target, and the bottler would like to understand better the sources of this variability and eventually reduce it. The process engineer can control three variables during the filling process: the percent carbonation (A), the operating pressure in the filler (B), and the bottles produced per minute or the line speed (C). Suppose that only two levels of carbonation are used so that the experiment is a 23 factorial design with two replicates. The data, deviations from the target fill height, are shown in Table 6-4, and the design is shown geometrically

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

Industrial Engineering

23 Factorial Design

Introduction

The largest effects are for carbonation (A = 3.00), pressure (B = 2.25), speed (C = 1.75) and the carbonation-pressure interaction (AB = 0.75), although the interaction effect does not appear to have as large an impact on fill height deviation as the main effects.

23 Factorial Design

Example

10

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

11

Industrial Engineering

23 Factorial Design
Main Effects Plot for Fill Hight Deviation
Fitted Means
A Carbonizat ion 2 1 B Pressure

Introduction

23

Factorial Design
Mean

0 -1 C Speed 2 1 -1 1

Example

1 0 -1 1

12

Industrial Engineering

23 Factorial Design
Residual Plots for Fill Hight Deviation
Normal Probability Plot Versus Fits
1.0
Residual

Introduction
99 90
Per cent

0.5 0.0 -0.5 -1.0

50 10 1 -1 0 Residual 1

23 Factorial Design

-2

2 Fitted Value

Histogram
6.0
Fr equency

Versus Order
1.0 0.5 0.0 -0.5 -1.0

Example

3.0 1.5 0.0

-1.0

-0.5

0.0 Residual

0.5

1.0

Residual

4.5

1 2

7 8

9 10 11 12 13 14 15 16

Obser vation Or der

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Industrial Engineering

23 Factorial Design
Interaction Plot for Fill Hight Deviation
Fitted Means
1 -1 -1 1 4 2

Introduction

A C arb o n izatio n -1 1

A Carbonization

23 Factorial Design
B Pressure

0 4 2 0

B P ressu re -1 1

Example
C Speed

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Industrial Engineering

23 Factorial Design
Interaction Plot for Fill Hight Deviation
Fitted Means
1 -1 -1 1 4 2

Introduction

A C arb o n izatio n -1 1

23 Factorial Design

A Carbonization 0 4 2 B Pressure 0

B P ressu re -1 1

Example
C Speed

15

Industrial Engineering

23 Factorial Design

Introduction

An engineer is interested in the effects of cutting speed (A), tool geometry (B), and cutting angle (C) on the life (in hours) of a machine tool. Two levels of each factor are chosen, and three replicates of a 23 factorial design are run. The results follow:

23 Factorial Design

Example

a. Estimate the factor effects b. Prepare an analysis of variance table, and determine which factors are important in explaining yield c. Plot the residuals versus the predicted yield and on a normal probability scale. Does the residual analysis appear satisfactory?
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Industrial Engineering

23 Factorial Design

Introduction

N=3 , = 104 , b = 119 , c = 127, b = 148, c= 113, bc= 164, bc= 127, (1) = 78

23 Factorial Design

Example

17

Industrial Engineering

23 Factorial Design

Introduction

N=3 , = 104 , b = 119 , c = 127, b = 148, c= 113, bc= 164, bc= 127, (1) = 78

23 Factorial Design

Example

18

Industrial Engineering

23 Factorial Design

Contrasts Introduction

23 Factorial Design

What is SST

Example

19

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

20

Industrial Engineering

23 Factorial Design

Introduction

23 Factorial Design

Example

21

Industrial Engineering

23 Factorial Design
Interaction Plot for Life in hours
Fitted Means
1 -1

Introduction
50

40

Cutting Speed

C u ttin g S p eed -1 1

23 Factorial Design

30

50

Tool Geometry

40

Tool G eo m etry -1 1

50

30

Example

40

Cutting A ngle

C u ttin g A n g le -1 1

30 -1 1 -1 1

22

Industrial Engineering

23 Factorial Design

Introduction

Main Effects Plot for Life in hours

Fitted Means
Cut t ing Speed 45.0 42.5 T ool Geomet ry

23

Factorial Design
Mean

40.0 37.5 35.0 -1 Cut t ing Angle 45.0 1 -1 1

Example

42.5 40.0 37.5 35.0 -1 1

23

Industrial Engineering

23 Factorial Design
Residual Plots for Life in hours
Normal Probability Plot
99 90 50 10 1 -5 -10 -5 0 Residual 5 10 30 36 42 Fitted Value 48 54 10

Introduction

Versus Fits

Residual

Per cent

5 0

23

Factorial Design

Histogram
6.0 10

Versus Order

Fr equency

Example

3.0 1.5 0.0

Residual
-5.0 -2.5 0.0 2.5 5.0 Residual 7.5 10.0

4.5

5 0 -5 2 4 6 8 10 12 14 16 18 20 Obser vation Or der 22 24

24

Industrial Engineering

23 Factorial Design

Introduction
99

Probability Plot of RESI1

Normal - 95% CI
M ean S tD e v N AD P -V a lu e 5.181041E -15 4.581 24 0.674 0.069

95 90

23

Factorial Design
Percent

80 70 60 50 40 30 20

Example

10 5

-15

-10

-5

0 RESI1

10

15

25

Industrial Engineering

23 Factorial Design

Introduction
Scatterplot of RESI1 vs FITS1
25 12.5 10.0 30 35 40 45 50 55 12.5 10.0 7.5 5.0 2.5 0.0 -2.5 -5.0 25 30 35 40 FITS1 45 50 55

23 Factorial Design
RESI1

7.5 5.0 2.5 0.0

Example

-2.5 -5.0

26