Proceeding, International Seminar on Industrial Engineering and Management Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

TEACHING DESIGN OF EXPERIMENT FOR INDUSTRIAL STATISTICS LABORATORY CLASS

Dedy Sugiarto. Industrial Statistics Laboratory, Industrial Engineering Department, Trisakti University Jl. Kyai Tapa No. 1 Jakarta-Indonesia 11440, telp. 62-21-5663232 Ext. 407
d_giarto@yahoo.com, dedy@trisakti.ac.id ABSTRACT Experience in designing and analyzing of experiments is very important for an industrial engineering student as his job later is related to the design, installation, and improvement of an integrated system. Books on design of experiments (DOE) have many exercises at the end of chapters that give students practise in the analysis of completed experiments, but students often receive little experience in DOE. Generally they only get practice analyzing data that calculated manually or using statistical software. DOE course also teaches many statistical principles of experimental design and sometimes not fun for students. The purpose of this paper is to share some ideas about teaching design of experiments by giving examples of simple experiments for laboratory class that integrates practice in designing realistic experiments, running the experiments, and also practice analyzing data in such a way that is easy to learn, fun, challenging, and memorable. This paper also gives series of simple experiment examples from literature that can done by students in laboratory classes or as home assignments. Key words : industrial engineering, design of experiments, simple experiments

1. INTRODUCTION Experience in designing and analyzing of experiments is very important for an industrial engineering student as his job later is related to the design, installation, and improvement of an integrated system. The course currently available in design of experiments (DOE) often tend to concentrate on more mathematical or statistical aspects of the subject rather than the techniques which are more practically useful. Books on design of experiments (DOE) have many exercises at the end of chapters that give students practise in the analysis of completed experiments, but students often receive little experience in DOE. Generally they only get practice analyzing data that calculated manually or using statistical software. The purpose of this paper is to share some ideas about teaching design of experiments by giving examples of simple experiments for laboratory class that integrates practice in designing realistic

experiments, running the experiments, and also practice analyzing data in such a way that is easy to learn, fun, challenging, and memorable. This paper also gives series of simple experiment examples from literature that can done by students in laboratory classes or as home assignments. In order to keep the experiment simple, all the control parameters were studied at 2 or 3-level using single factor or factorial experiments. These simple experiments will form a student foundation for studying the parameters at 3-level and higher for the wider application in real-life situations or using other techniques of DOE like response surface, taguchi or mixture experiments. 2. DESIGN OF EXPERIMENT OVERVIEW An experiment is a test or series of tests in which purposeful changes are made to the input variables of a process or system so

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Proceeding, International Seminar on Industrial Engineerig and Management

Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

that we may observe and identify the reasons for changes that may be observed in the output response (Montgomery 2005). DOE is a methodology for systematically applying statistics to experimentation. DOE lets experimenters develop a mathematical model that predicts how input variables interact to create output variables or responses in a process or system (Lye, 2005). The following steps are useful while one may be performing an industrial experiment (Antony, 1998),: 1. Definition of the objective of the experiment. 2. Selection of the response or output. 3. Selection of the process variables or design parameters (control factors), noise factors and the interactions among the process variables of interest. (Noise factors are those which cannot be controlled during actual production conditions, but may have strong influence on the response variability. The purpose of an experimenter is to reduce the effect of these undesirable noise factors by determining the best factor level combinations of the control factors or design parameters. For example, in an injection moulding process, humidity and ambient temperature are typical noise factors.) 4. Determination of factor levels and range of factor settings. 5. Choice of appropriate experimental design. 6. Experimental planning. 7. Experimental execution. 8. Experimental data analysis and interpretation. There are many types of DOE techniques that include general factorial, twolevel factorial, fractional factorial, response surface designs, mixture designs and taguchi designs. General full factorial designs (designs with more than two-levels) is useful for small

screening experiments. Response surface methods are used to examine the relationship between one or more response variables and a set of quantitative experimental variables or factors. These methods are often employed after you have identified a "vital few" controllable factors and we want to find the factor settings that optimize the response. Designs of this type are usually chosen when we suspect curvature in the response surface (Minitab, 2000). Special class of response surface experiments in which the product under investigations is made up of several components of ingredients. Response is a function of the proportions of different ingredients in the mixture. The quantities of components, measured in weights, volumes, or some other units, add up to a common total. Mixture experiment example is the taste of lemonade depends on the proportions of lemon juice, sugar, and water (Minitab, 2000). Taguchi designs provide a powerful and efficient method for designing products that operate consistently and optimally over a variety of conditions. In robust parameter design, the primary goal is to find factor settings that minimize response variation, while adjusting (or keeping) the process on target (Minitab, 2000). 3. SIMPLE EXPERIMENT EXAMPLES Case 1 : Pop corn experiment For example, we may want to investigate the influence of pop corn brands on the proportion of un-popped kernels (minimize). We use completely randomize design or without blocking of experimental unit for this single factor experiment. There are tree levels for brand (A, B and C) and tree replications for each lavel. We use one hundred kernels for each trial and 3,5 minutes to make pop corn on stove. We wish to test hypotheses about the treatment means, and our conclusion will apply only to the factor levels considered in the analysis
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Proceeding, International Seminar on Industrial Engineering and Management Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

Ho : 1 = 2 = . = a H1 : i j for at least one pair (i,j)

Table 1. The result of pop corn experiment

Un-popped kernels proportion 0,04 0,05 0,11 0,00 0,08 0,13 0,03 0,03 0,08

Run order Brand C Brand C Brand B Brand A Brand C Brand B Brand A Brand A Brand B

Picture 1. Three brands of pop corn

The small p-values for the brand (p = 0.007) that lower than ( 0.05) suggest there is significant effect of brand on proportion of un-popped kernels. Individual 95% confidence interval for mean of three brand suggest that brand A has significantly difference with brand B.
One-way ANOVA:
Source P Brand 0,007 Error Total S = 0,02134 74,13% DF 2 6 8 SS 0,011356 0,002733 0,014089 MS 0,005678 0,000456 R-Sq(adj) = F 12,46

R-Sq = 80,60%

Picture 2. Medium pan with cover

Case 2 : Time to boil water experiment For example, we may want to investigate the influence of pan size and cover on the time in minute to boil water. We use general full factorial design and completely randomize design or without blocking of experimental unit. Single. There are two-level for each factor and 3 replications for each combination. Dimensions of small pan is 14 cm for diameter and 10 cm for height. Dimensions of medium pan is 18 cm for diameter and 11 cm for height. Volume of water is 600 ml.

Picture 3. Popped and un-popped kernels from tree brands

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Proceeding, International Seminar on Industrial Engineerig and Management

Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

rensponse suggests that small and cover (yes) give lower time to boil water.
General Linear Model: time (minutes) versus pan size, cover
Factor pan size cover Type fixed fixed Levels 2 2 Values small, medium yes, no

Picture 4. Small pan, medium pan and glass cover

Analysis of Variance for time (minutes), using Adjusted SS for Tests Source F P pan size 4.90 0.058 cover 3.65 0.093 pan size*cover 3.30 0.107 Error Total S = 0.246374 44.58% DF 1 1 1 8 11 Seq SS 0.29768 0.22141 0.20021 0.48560 1.20489 Adj SS 0.29768 0.22141 0.20021 0.48560 Adj MS 0.29768 0.22141 0.20021 0.06070

R-Sq = 59.70%

R-Sq(adj) =

Picture 5. Medium pan with cover on stove Table 2. The result of time to boil water experiment
RunOrder 1 2 3 4 5 6 7 8 9 10 11 12 pan size medium small small small medium medium medium small small medium medium small cover no yes yes no no yes yes yes no yes no no time (minutes) 3.92 3.07 3.00 3.53 3.63 3.83 3.20 3.22 3.75 3.98 3.50 3.60

Unusual Observations for time (minutes) time Obs (minutes) Fit SE Fit Residual Resid 7 3.20000 3.67000 0.14224 -0.47000 -2.34 R

St

R denotes an observation with a large standardized residua

Main Effects Plot (data means) for time (minutes)
3.70 3.65 Mean of time (minutes) 3.60 3.55 3.50 3.45 3.40 3.35 small medium yes no pan size cover

The small p-values for the pan size (p = 0.058) and cover (p = 0.093) that lower than (0.10) suggest there is enough significant effect of pan size and cover on time to boil water. Interaction of pan size and cover is not significant. Mean plot of

Picture 6. Mean plot of response

Case 3 : Painting experiment We may want to investigate the influence of painting methods (dipping, spray and brush)

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Proceeding, International Seminar on Industrial Engineering and Management Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

and brand of paint on visual quality using 10 point scale. As a standard for point 10, we use sample product from PT. Safira Tumbuh Berkembang (wooden toys producer). General full factorial design and completely randomize design used in this experiment. There are tree levels for painting methods and two levels for paint brands and three replications for each combination. This experiment is part of Manufacturing Industrial Design Lab. in Industrial Engineering Department Trisakti University. The end product is wooden toy train.

Picture 9. Dipping method for painting

Picture 10. Spraying method for painting

Picture 7. Materials and equipments of painting experiment

The results and anlysis of this experiment are not written on this paper. 4. CONCLUSION 1. This paper has shown the benefit of employing a systematic approach to simple experimentation using DOE, rather than utilising a trial and error approach 2. The paper has also illustrated some simple experiments that can be used as a powerful teaching and learning tool in industrial statistics laboratoy. 3. These simple experiments will form a student foundation for studying DOE for the wider application in real-life situations or using other techniques of DOE like response surface, taguchi or mixture experiments. 5. REFERENCES

Picture 8. Preparation of experimental unit

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Proceeding, International Seminar on Industrial Engineerig and Management

Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

(a) Antony J, N Capon (1998). Teaching Experimental Design Techniques to Industrial Engineers. Int. J. Engng Ed. Vol. 14, No. 5, pp. 335-343 (b) Antony J, N Capon. Some key things industrial engineers should know about experimental design. Logistics Information Management Volume 11 Number 6 1998 pp. 386392 (c) Hunter WG. 101 Ways to Design an Experiment, or Some Ideas About Teaching Design of Experiments. 1975. http://williamghunter.net/articles/101d oe.cfm (d) Lye LM. Tools and toys for teaching design of experiments methodology. 33rd Annual General Conference of the Canadian Society for Civil Engineering. 2005 (e) Mackisack M (1994). Incorporating Favourite Experiments: An Addendum to What is the Use of Experiments Conducted by Statistics Students?. Journal of Statistics Education v.2, n.1 (f) Martinez-Dawson R (2003). Incorporating Laboratory Experiments in an Introductory Statistics Course. Journal of Statistics Education Volume 11 (g) Minitab (2000). Users Guide 2 : Data Analysis and Quality Tools Release 13 for Windows (h) Montgomery DC (2000). Design and Analysis of Experiments. New York : John Wiley & Sons, 2005

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Proceeding, International Seminar on Industrial Engineering and Management Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

APPENDIX. Some simple Experiments Examples.

No Response 1 taste (maximize), un-popped kernels (minimize) of Microwave popcorns 2 quality of slides Photography 3 time to boil water 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 distance golf ball hit on full squash ball rebound distance distance football kicked number of pins down water evaporation car acceleration number of baskets thrown letter delivery time speed running distance paper aeroplane flew longjump distance time to swim 25m time to deliver pizza time to boil water virus scan time Factors brand, time, power, height (on bottom or raised)

19 20 21

22 film speed, lighting, shutter speed pan type, burner size, cover tee height, ball age, club type ball type, ball age, ball temperature kick style, angle to goal, angle of ball bowling ball weight, spin, position for throw surface area, sun or shade, volume at start time to gear change, road surface, car type (?) ball size, distance from net post code, mailbox or post office, town (?) distance, terrain, time of day design, paper weight, angle runup distance, shoes on or off, L or R foot shirt on or off, flippers, goggles weight crust thickness, garlic bread, Coke amount of water, lid on or off, size of pan RAM cache, program size, operating system (?)

distance cricket ball hit number of corns popped/100 time to complete fixed course on bicycle and pulse rate at finish yield of popcorn

23

quality of bread, especially the total rise how well twins, who had colds, slept during the night quality of slides made close up with flash attachment on camera growth rate of algae in salt water aquarium taste of Koolaid

24

25

weight of bat, wearing gloves (?) pot diameter, oil or margarine seat height (26, 30 inches), generator (off,on), tire pressure (40, 55 psi) brand of popcorn (ordinary, gourmet), size of batch (1/3,2/3 cup), popcorn to oil ratio (low, high) amount of yeast, amount of sugar, liquid (milk, water), rise temperature, rise time number of pills, amount of cough syrup, use of vaporizer speed of film, light (normal, diffused), shutter speed hours of illumination, water temperature, specific gravity of water temperature, amount of sugar, food prior to drink (water, salted popcorn) direction in which radio is facing, antenna angle, antenna slant blending speed, amount of water, temperature of water, soaking time before blending charge time, digits fixed, number of calculations performed clothes dryer (A,B), temperature setting, load

26

27

28

29

strength of radio signal from particular AM station in Chicago blending time for soy beans

30

operation time for pocket calculator time until dryer stops

31

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Proceeding, International Seminar on Industrial Engineerig and Management

Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

32

time to boil water

33

hours of relief from migraine headache taste comparison of homemade yogurt and commercial brand time required to run up steps and heartbeat at top length of flight of model airplane

pan (aluminum, iron), burner on stove, cover for pan (no, yes) aspirin buffered? (no, yes) dose, water temperature 44 amount of milk powder added to milk, heating temperature, incubation temperature pack on back (no, yes), footwear (tennis shoes, boots), run (7, 14 flights of steps) width to height ratio of sheet of balsa wood, slant angle, dihedral angle, weight added, thickness of wood level of coffee in cup, devices (nothing, spoon placed across top of cup facing up), speed of walking type of stitch, yarn gauge, needle size type of drink (beer, rum), number of drinks, rate of drinking, hours after last meal size of order, time of day, sex of server brand of gasoline, driving speed, temperature stamp (first class, air mail), zip code (used, not used), time of day when letter mailed side of face (left,

whiskers 3 days after shaving

34

35

45

36

46 47

number of times (out of 15) that correct gender of passerby was determined by experimenter with poor eyesight wearing no glasses number of shot that penetrated a one foot diameter circle on the target height of cake density of photographic film length of rubber band before it broke speed of H.O. scale slot racers time for car to cover one-quarter mile time to dissolve table salt taste of stewed chicken angle necessary to make object slide number of kicks necessary to start motorcycle

right), beard history (shaved once in two years0-sideburns, shaved over 600 times in two yearsjust below sideburns) eyes used (both, right), location of observer, distance

distance to target, guns (A,B), powders(C,D) oven temperature, length of heating, amount of water strength of developer, temperature, degree of agitation brand of rubber band, size, temperature viscosity of oil, type of pick-up shoes, number of teeth in gear type of tire, brand of gas, driver (A,B) temperature, stirring rate, amount of solvent amounts of cooking wine, oyster sauce,sesame oil type of surface, object (slide rule, ruler, silver dollar), pushed? (no,yes) ambient temperature, choke setting, number of

37

how much coffee spilled while walking

48 49

38 39

cost of knitting scarf, dollars per square foot time to get steel ball through a maze cost of order of french fries, in cents per ounce gas mileage for car number of days required for letter to be delivered to another city length of

50 51

40 41 42

52 53

54

43

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Proceeding, International Seminar on Industrial Engineering and Management Menara Peninsula, Jakarta, August 29-30, 2007 ISSN :

55

time to bake biscuits

56

quantity of suds produced in kitchen blender toys child chose to sleep with

57

58

59

60 61

correct answers on simple arithmetic test, time required to complete test, words remembered (from list of 15) bite, smoking characteristics, aroma, and taste of tobacco mixture time to melt ice points in games of sheepshead, a card game taste of pancakes, consensus of group of four living together time to get sun burned soundness of sleep, average reading from five persons

charges temperature, location in oven, biscuits covered while baking? (no,yes) temperature of water, amount of grease, amount of water conditioner person putting daughter to bed (mother, father), bed time, place (home, grandparents) amount of light in room, type of music played, volume

65

clearness and quality of sound, and absence of noise time to filter

66

67 68

time to go down ski slope four quality characteristics of pizza time for seeds to germinate quality of ground malt for brewing beer taste of drink from paper cup

69 amounts of added Turkish, Latakia, and Perique tobaccos temperature, humidity, rock salt number of cards dealt at one time, position of picker relative to the dealer amounts of flour, eggs, milk brand of suntan lotion, altitude, skier amount of sleep the night before, substantial exercise during the day? (no, yes), eat right before 70

71

62

63 64

number of swings and duration of these swings obtained from an automatic infant swing Source : Lye LM (2005), Mackisack M (1994) and Hunter WG (1975) The experiments are listed in the form Response/factors. For those marked (?) it was difficult to control extraneous variation, and significant results were not obtained.

72

going to bed? (no, yes) brand of tape deck used for playing music, bass level, treble level, synthesizer? (no, yes) type of filter paper, beverage to be filtered, volume of beverage type of ski, temperature, type of wax ambient temperature for dough when rising, amount of vegetable oil, number of onions amount of fertilizer, location of seeds (3 x 3 Latin square) speed of kitchen blender, batch size of malt, blending time soft drink (A,B), container (can, bottle), sugar free? (no, yes) child's weight (13, 22 pounds),spring tension (4, 8 cranks), swing orientation (level, tilted)

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