0E3l0N 0F EXPERlVENT3 0EVY3TlFlE0 n Larry 3coll

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By Larry Scott

Design of experiments (DOE) is a structured approach to
modeling components, systems or processes using a test
sequence called an experimental array. In the test sequence,
changes are made to the input variables, which in-turn affects
performance of one or more quality characteristics as captured
in the output. Figure 1
illustrates a full-factorial ar-
ray (2
k
) with two variables
(k) at two levels. In this four
run array, each variable level
is coded with a plus (+) and a
minus (-) to represent the
extreme values at which each
variable will be tested. The
array outlines all tests per-
formed on glass substrates
from two manufacturers (A-
and A+) etched with two
concentrations of acid (B-
and B+).

The experimental array
displays an equal number of
pluses and minuses for each
variable. Array balance en-
sures that each input variable can be quantified independently.
Once all the experiments are run, a response variable analysis
correlates the input and response variables in a simplified
model, y =
0
+ X. These predictive models assist in ma-
king knowledge based decisions by demonstrating the input
(x) and output (y) relationship quantitatively
(). Understanding these relationships, an
engineer can readily adjust an input variable
to target a performance for a desirable
quality characteristic.

DOE is an efficient and cost effective means
for solving problems, as well as modeling
products and processes. Yet, many organiz-
ations continue to apply the one-factor-at-a-
time (OFAT) linear test methodology. The
OFAT method requires large numbers of
experiments and is incapable of modeling
interactions between system variables. On
the other hand, design of experiments relies
on a parallel testing procedure to model
relationships, y = f (x), between main effects
(A, B) and variable interactions (AB)
relative to a quality characteristic (y).
Parallel testing minimizes development time and costs, adding
value and reducing time-to-market.

The ability to quantify variable interactions is a major benefit
of DOE. Interactions occur when the effect of one factor
depends on the level of a second factor. Anderson defines an
interaction as the combined change in two factors that
produces an effect greater (or less) than that of the sum of
effects expected from either factor alone.
1
Interaction
effects reveal themselves in two possible modes, synergistic or
antagonistic. Knowing the combination of factor levels that
produces a desired effect could contribute to a significant
improvement in performance.

Interaction and main effect values from the acid etch tests are
tallied in Figure 1. Variable effects and betas () measure
how main and interaction variables contribute to the output
in this case silica precipitates in an acid-etch bath. Effect
values indicate a factors relative level of influence on the
system under investigation. In this test array, all factors
influenced the quality measure as reflected by their respective
effects. Betas, which depend on the number of factor levels
tested, quantifies each factor represented in the prediction
equation. The resultant prediction equation for the acid-etch
data is

y = 24.0 - 2.0 A + 10.5 B - 7.5 AB.

The acid-glass type interaction
2
(AB) is illustrated graphically
in Figure 2. The quality characteristic - precipitate volume -
varies depending on acid concentration and to a lesser degree,
glass type. Since the two main effects are involved in an
interaction, selecting variable levels that achieve a desired
performance low precipitates are determined from the
interaction plot. The interaction is attributed to compositional
differences in the glass substrates. However, rather than make
specification changes for the substrates, the interaction plot
reveals that the low acid concentration
provides a sufficient etch for both glass
types. Once lower acid levels were
implemented on the manufacturing floor,
rework was reduced, plus equipment
maintenance costs were improved. This
single change led to several hundred
thousand dollars in annual savings.

Design of experiments offers advantages
over other experimental methodologies, like
OFAT. Parallel testing reduces development
resources and the methodology allows for
the quantification of factor interactions.
The availability of software simplifies the
data analysis. DOE software can readily
analyze large volumes of data and quickly
construct complicated prediction models
from the results. DOE offers the opportu-
nity to reduce development and manufacturing costs by
improving system efficiency, while simultaneously improving
product performance. There is one catch however you must
actually apply the method in order to reap its benefits!

1. Anderson, Whitcomb; DOE Simplified, 2000.
2. Interaction graphic generated using Design-Expert software.
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