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GeneralFactorialTutorial (Part1CategoricTreatment)
IntroductionACaseStudyonBatteryLife
DesignExpertsoftwareversion8offersaGeneralFactorialoptiononthe Factorialtab.IfyouhavecompletedtheGeneralOneFactorTutorial (recommended),youveseenhowthisoptionhandlesonemultilevel,categorical factor.Inthistwoparttutorialyouwilllearnhowtosetupadesignformultiple categoricalfactors.Part2showsyouhowtoconverttrulycontinuousfactors,such astemperature,fromcategoricaltonumerical.Withthisyoucangenerate responsesurfacegraphsthatprovideabetterperspectiveofyoursystem. Theexperimentinthiscase,whichcomesfromMontgomerysDesignandAnalysis ofExperiments,seeksconsistentlylonglifeinabatterythatwillbesubjectedto extremesinambientconditions.Itevaluatesthreematerials(factorA)atthree levelsoftemperature(factorB).Fourbatteriesaretestedateachoftheninetwo factorcombinationsinacompletelyrandomizeddesign.Theresponsesfromthe resulting36runsareshownbelow. Material Type A1 A2 A3 130 74 150 159 138 168 Temperature (deg F) 15 155 180 188 126 110 160 34 80 136 106 174 150 70 40 75 122 115 120 139 20 82 25 58 96 82 125 70 58 70 45 104 60

Generalfactorialonbattery(responseislifeinhours) Thefollowingquestionsmustbeanswered: Howdoesmaterialtypeandtemperatureaffectbatterylife? Doanymaterialsprovideuniformlylongliferegardlessoftemperature?

Thesecondquestion,ifitcanbeansweredintheaffirmative,leadstothebigpayoff: abatterythatwillberobusttotemperaturevariationsinthefield.Thiscasestudy providesagoodexampleofapplyingstatisticalDOEforrobustproductdesign.

DesigntheExperiment
Tobuildthedesign,chooseFile,New Designasshownbelow(ortosavestrokes, simplyclicktheblanksheeticon()onthetoolbar).

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 Startinganewdesignviamenu(option:clickblanksheeticon()onthetoolbar) ThenfromthedefaultFactorialtab,clickGeneral Factorial.Choose2asthe numberoffactors.IfyouareinHorizontalentrymode,changeittoVertical. (DesignExpertwillrememberthisthenexttimeyousetupadesign.)

Selectingnumberoffactorsforgeneralfactorialdesign EnterMaterialforfactornameA(Categoric).KeyinthewordTypeasyourUnits. Enterthevalue3forthenumberoflevels.ChangethetreatmentnamestoA1,A2 andA3.NoticethatTypeinthefarleftcolumndefaultstoNominal(named)as opposedtoordinal(ordered).Thisdifferenceinthenatureoffactorsaffectshow DesignExpertcodesthecategoricallevels,whichchangesthemodelcoefficients reportedunderANOVAinthesubsequentresponseanalysis.Yourdesignshould nowappearasthatshownbelow.

Enteringmaterialasanominalfactor Tutorialssuchasthisoneongeneralfactorialswillquicklygetyouuptospeedon howtouseDesignExpertsoftware,butitdoesnotserveasastatisticalprimerfor designandanalysisofexperiments.Ifyoucravesuchdetails,Helpisatyourfinger tips!Forexample,gotoHelp,Contentsandworkyourwaydownthetree

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structurethroughthefactorialbranchestoGeneral (Multi-Level) Factorial Design.Notethedetailsonthedistinctionincategoriccontrasts(Nominalvs Ordinal).

Helpongeneralfactorialdesign CloseHelpbypressingXonitswindow.NowenterfactorBdatabykeyingin TemperatureforfactornameB(Categoric),deg Fforunits,3forthenumberof levels,and15,70and125forthelevels.PressNominal,clickthearrowonthe droplist,thenchooseOrdinalasshownbelow.ThischangefromNominalto Ordinalindicatesthatalthoughthisfactorisbeingtreatedcategorically(for example,duetocontrolsofferingonlythethreelevels),temperatureisreallya continuousfactor.ClickContinueatthescreensfarlowerright.

EnteringinformationonfactorB
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Enter4forreplicates.Thenumberofruns(36)wontbeupdateduntilyoupress theTabkeyormovefromthecell.Leavetheblocksoptionalonebecausethese experimentsarecompletelyrandomized.

Enteringthenumberofreplicates ClickContinuetomoveontotheentryscreenforresponses.Leavethedefault responsesat1.EnternameasLifeandunitsashours. Nowwewillwalkyouthroughacalculationofpowertheabilityofyour experimenttodetectmeaningfuldifferencesintreatments.Ifyoudotoofewruns andunderpoweryourexperiment,animportantchangeinresponse(thesignal) willbecomeobscuredbynormalsystem/testvariation(thenoise).Thatwould beawasteoftimeandmaterials.DesignExpertmakesthecalculationofpower easyandputsitinupfrontinthedesignbuildingprocesssoyouhaveachanceto bolsteryourexperiment,ifnecessary.Letsassumethatbatterylifemustimprove byatleast50hourstobeofanyinterestandthatqualitycontrolrecordsproducea standarddeviationof30.Enterthesevaluesasshownbelow,Tab(orclick)outof 30,andDesignExpertthencalculatesthesignaltonoiseratio.

Responseentryscreen PressContinuetoseethepowerofthisdesignforthedifferencethattheengineers hopetodetect,ataminimum.Itiscalculatedtobe94.5%probabilityofseeinga difference(delta)assmallas50hours.Thisexceedstheruleofthumbforpower of80%ataminimum,thusitcanbeconcludedthattheplanneddesignwillsuffice.

Powercalculation
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ClickContinuetocompletethedesignspecificationprocess.DesignExpertnow displaysthe36runs(inrandomorder)fromthe3x3factorialdesignwithfour replicates.

AnalyzetheResults
Tosavetime,simulatetheexperimentalresultsbyrightclickingtheresponse headerandselectingSimulate Response.(Aheadsupforstatisticseducators: YoucanbuildyourownsimulationsviatheDesignTools.Feelfreetobringupthe controlsforthisandpressHelpfordetailsonusingit.)

Choosingasimulation ClickthefilenamedBattery.simandOpenit.Ifthisfiledoesnotappear,locate thedatafolderbyfindingtheDesignExpert8datafolderintheinstalledStatEase programgroupunderyourAllProgramsmenu.Youcanalsodownloadthetutorial filesbygoingtotheHelpMenuTutorials.Ifyoustillcannotfindthissimfile,feel freetoemailsupport@statease.com.Youshouldnowseedataslowlyflowinfrom theexperiment(weaddedadelayinthesimulatorsoyoucanreadtheresultsas theygetenteredbythecomputeralso,thismakesitseemabithardertodothe runs:Letsnotmakethingslooktooeasy!).Thisisagoodtimetopreserveyour work:SelectFileandSave As.ChangethefilenametoBattery.dxpandSave. ThenundertheAnalysisbranchoftheprogram,clickthenodelabeledR1:Life. Younowseeoptionsforperformingresponsetransformations.

Firststepintheanalysistransformationoptions
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LeavethetransformationatthedefaultofNoneandgoaheadandclickthe Effectsbuttondisplayednextinthetoolbarforresponseanalysis.DesignExpert nowprovidesaninitialeffectselectionanddisplaysitgraphicallyonaspecialized statisticalplotcalledahalfnormal.

Initialeffectselection Theprogramdisplaystheabsolutevalueofalleffects(plottedassquares)onthe bottomaxis.TheprocedureisdetailedinapresentationbyPatrickWhitcombon GraphicalSelectionofEffectsinGeneralFactorials(2007FallTechnical ConferencecosponsoredbytheAmericanSocietyforQualityandtheAmerican StatisticalAssociation)contactStatEaseforacopy. DesignExpertpreselectedtwooutstandingeffectsthemaineffectsoffactorsA andB.Youcan,andinthiscaseshould,modifythedefaulteffectselection.Move yourmousecursorovertheunlabeledsquareandclickit.(Notethatthisgoesboth ways,thatis,youcandeselectchoseneffectswithasimplemouseclick.)

Anothereffectchosen InteractionABisnowidentified.NoticethatDesignExpertadjuststhelineto excludethechoseneffects.Youwillgainmorepracticeontheuseofhalfnormal

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plotsforpickingeffectsintheTwoLevelFactorialTutorial.Itsbesttonowpress aheadinthiscase. Foranumericalcalculationoftheeffects,presstheEffects ListbarontheEffects Toolthatyouseefloatingonyourscreen(wemovedittoconvenientplacefor illustrativepurposes).

Effectslist NoticethedesignationMfortheselectedmodeltermsA,BandABandthee nexttothepureerrorlineinthisstatisticalspreadsheet.Youmaybewondering whytherearesomanyestimatesofpureerror.(Ifnot,skipahead!)Eachsubgroup of4replicationsprovides3degreesoffreedom(df)ofpureerror.Thiswasdone forall9factorcombinations(3x3)whichyields27df(=3*9)intotalforestimating pureerror. Thisscreenprovidesmanyfeaturesformodelselection,whichwillbecoveredin tutorialsonresponsesurfacemethods(RSM). ClicktheANOVAbuttontoseetheanalysisofvarianceforthischosenmodel.If youdonotseeannotationsinbluetextasshownbelow,selectView,Annotated ANOVA.

AnnotatedANOVAReport

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ScrolldownorpressbookmarksonthefloatingtooltoseepostANOVAstatistics suchasRSquared.Asyoucanconcludeforyourselfbyreadingtheannotations, theresultslookgood.Furtherdownthereportaredetailsofthemodelbasedon nominalcontrasts.WeprovideabreakdownonthisintheExperimentDesign MadeEasyworkshop.Tokeepthistutorialmoving,itsbestnottogetbogged downinthemathematicsofmodelingcategoricalfactors,sopressaheadtothe Diagnosticsbuttonandexaminetheresidualgraphs.Bydefaultyouseethe normalplotofresiduals,whichideallyfallmoreorlessinline.Thepatternhereis notbadlyabnormal,sodonotworry.

NormalplotofresidualslooksOK Thetedious,butnecessary,modelfittingandstatisticalvalidationisnow completed,soyouarefreeandcleartofinallyassesstheoutcomeoftheexperiment anddecidewhetheranymaterialsprovideuniformlylongbatteryliferegardlessof temperature.

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PresenttheExperimentalFindings
ClicktheModel Graphstoviewthelongawaitedresults.DesignExpert automaticallypresentstheABinteractionplotidentifiedbytheTermwindowon thefloatingFactorsTool.

DefaultmodelgraphinteractionplotwithAonbottom(X1)axis Inamomentwewillleadyouthroughaseriesofstepstodevelopacompelling presentation.Butfirst,hereisaheadsuponplottingthemaineffects,ratherthan theinteraction.Skipthispartifyouareanxioustopressahead.Otherwise,choose theOneFactorplotviewviatheViewmenu,orbysimplypressingtheappropriate buttononthefloatingGraphsTool.Anotherwaytobringupaonefactorplot(the maineffectofAorB,inthiscase)isbyclickingthedownlistarrow(j)forthe TermselectionontheFactorsTool.Tryalltheseapproachesifyoulike,butexpect tobewarnedaboutpresentingmaineffectsoffactorsthatinteract.Thiscanbe verymisleading.Inthiscaseitwillbeamistaketolookateithermaterialor temperatureeffectsalone,becauseonefactordependsontheother.Letsexplore thisinteractionfurtherandmakeitasclearaspossibleforreportingpurposes. Ifyougotsidetrackedwhileexploringtheprogramsgraphoptions,pressthe InteractionplotontheGraphsTool.

Graphstoolinteractionplotselected RightclicktheTemperaturefactoronthefloatingFactors Toolandchangeitto theX1 Axis,thusproducinganinteractiongraphwiththeordinalfactordisplayed inacontinuousmannerandthenominalfactor(material)laidoutdiscretelyas separatelines.Thismakesiteasiertointerpretyourresults.

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 Effectgraphwithtemperatureonbottomaxis Toseehowthesoftwareidentifiespoints,clickthehighestone(green)attheupper leftofthegraph.Theresultisshownbelow.

Pointhighlightedforidentification Notehowtotheleftoftheplotthesoftwareidentifiesthepointby: theactualresult(188) standardordernumber(7) runnumber(duetorandomizationyoursmaydifferfromthatshown) factorlevels(temperatureof15withmaterialA2).

Theactualresultsarerepresentedbyvariouscoloredcircles.Youcanalsoclickon thenoncircularsymbols(square,triangleordiamond)todisplaythepredicted outcomeandleastsignificantdifference(LSD).Trythis! Toproduceacleanerlookingplot,gotoViewanddeselectShow Legend.

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Legendturnedoff Letsdosomemorecleanupforreportpurposes:Rightclickoverthegraphand selectGraph Preferences. Rightclickmenuselectionforgraphpreferences NowclicktheAll Graphstabandturnoff(uncheck)theShow design points on graphoption,asshownbelow.

Turningoffdesignpoints PressOK.Thisisanoptionalsidetrackonthistutorial:Tohaveyourgraphlook likethatshownbelowforreportingpurposes,dothefollowing:Edit,Copy from DesignExpert,thenEdit,Paste intoMicrosoftWord.

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Interaction
A: Material
200

A2
150

A3 A1

Life

100

50

15

70

125

B: Temperature

Cleanlookinginteractiongraph Fromthisgraphyoucanseethatallthreematerialsworkverywellatthelow temperature(15degrees).BasedontheoverlappingLSDbars,itwouldbefairto saythatnomaterialstandsoutatthislowtemperatureendofthescale.However, theA1materialclearlyfallsoffatthe70degreetemperature,whichwouldbe encounteredmostoften,soitmustberejected.Noneofthematerialsperformvery wellatthehighesttemperature(125degrees),buttheupperendoftheLSDbarfor A2barelyoverlapsthebottomendoftheLSDbarforA3.Therefore,withrespectto temperaturesensitivity,materialA3maybethemostrobustmaterialformaking batteries. Finally,ifyoudohaveanopportunitytopresentgraphicsincolor,heresadazzling newandeasywaytodisplaygeneralfactorialeffectswithDesignExpert:Click3D SurfaceonthefloatingGraphs Tool.

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3Dsurfaceplot Nowplaceyourmousecursoronthegraphnoticethatitchangestoahand(,). Whilepressingtheleftmousebutton,spinthegraphsothetemperatureaxisisat thebottom.(Alternatively,tomatchourgraphmostprecisely,selectView,Show Rotationandentercoordinatesofh(horizontal)20andv(vertical)80.)

3Dsurfaceplotrotatedslightlyforabetterview The3Dviewpresentsadifferentperspectiveofthegeneralfactorialeffectsmore onamacroleveloftheoverallexperimentallandscape.Nowtheinferiorityof materialA1(redbars)becomesobvious:Theothertwomaterialstoweroveritat themidtemperatureof70degreesF.Clearlythenextstepistoeliminatematerial A1fromcontentionandperhapsdosomefurtherinvestigationsonA2andA3.

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