TEACHING DESIGN OF EXPERIMENT FOR INDUSTRIAL STATISTICS LABORATORY CLASS

d_giarto@yahoo.com / dedy@trisakti.ac.id

Dedy Sugiarto

Jakarta, 2007
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Problem :
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

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Objective :
to share some ideas about teaching DOE 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.

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Where do the ideas come from ?

Antony J, N Capon. Teaching Experimental Design Techniques to Industrial Engineers. Int. J. Engng Ed. Vol. 14, No. 5, , 1998 pp. 335343 Antony J, N Capon. Some key things industrial engineers should know about experimental design. Logistics Information Management Volume 11 Number 6 1998 pp. 386392 Hunter WG. 101 Ways to Design an Experiment, or Some Ideas About Teaching Design of Experiments. 1975. http://williamghunter.net/articles/101doe.cfm Lye LM. Tools and toys for teaching design of experiments methodology. 33rd Annual General Conference of the Canadian Society for Civil Engineering. 2005 Martinez-Dawson R. Incorporating Laboratory Experiments in an Introductory Statistics Course. Journal of Statistics Education Volume 11, Number 1, 2003. http://www.amstat.org/publications/jse/v11n1/martinez-dawson.html

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

DESIGN OF EXPERIMENT OVERVIEW

DOE is a methodology for systematically applying

statistics to experimentation (Lye, 2005). 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 that we may observe and identify the reasons for changes that may be observed in the output response (Montgomery 2005) ] There are many types of DOE techniques that include general factorial, two-level factorial, fractional factorial, response surface designs, mixture designs and taguchi designs.
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Some examples of simple experiments from Lye LM (2005), Mackisack M (1994) and Hunter WG (1975) :
No 1 Response or output Factors or input variables

taste (maximize), unbrand, time, power, height (on bottom or popped kernels raised) (minimize) of Microwave popcorns virus scan time time to boil water RAM cache, program size, operating system pan type, burner size, cover, amount of water, lid on or off, size of pan

2 3

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No Response

Factors

4
5

distance paper aeroplane flew

design, paper weight, angle

blending time for soy beans blending speed, amount of water, temperature of water, soaking time before blending height of cake oven temperature, length of heating, amount of water

length of rubber band before it broke

brand of rubber band, size, temperature

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Industrial Statistics Laboratory Industrial Eng. Dept Trisakti University

Lab. Form for DOE Module :

Names:____________________ Period:______________
Purpose of experiment :

Date:_______________

Hypothesis:
Materials: Procedures: Results and Analysis using MINITAB : Conclusion:
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

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.
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

 We wish to test hypotheses about the

treatment means, and our conclusion will apply only to the factor levels considered in the analysis Ho : 1 = 2 = . = a H1 : i j for at least one pair (i,j)
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Randomization using Minitab :

Run order Brand C Brand C Brand B Brand A Brand C Brand B Brand A Un-popped kernels proportion

Brand A
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Brand B

Picture 1. Three brands of pop corn

Picture 2. Processing of pop corn

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The results of experiment :

Run order
Brand C Brand C Brand B Brand A Brand C Brand B Picture 3. Popped and unpopped kernels from tree brands Brand A Brand A Brand B Un-popped kernels proportion 0,04 0,05 0,11 0,00 0,08 0,13 0,03 0,03 0,08

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Minitab Output :
One-way ANOVA: Pooled StDev = 0,02134 Source DF SS MS F P Brand 2 0,011356 0,005678 12,46 0,007 Error 6 0,002733 0,000456 Total 8 0,014089 S = 0,02134 R-Sq = 80,60% R-Sq(adj) = 74,13%
Level Brand A Brand B Brand C N 3 3 3 Mean 0,02000 0,10667 0,05667 StDev 0,01732 0,02517 0,02082 Individual 95% CIs For Mean Based on Pooled StDev ---+---------+---------+---------+-----(-------*-------) (-------*------) (------*-------) ---+---------+---------+---------+-----0,000 0,040 0,080 0,120

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Interpreting the Results :

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.
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

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.
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Randomization using Minitab :

RunOrder pan size
1 medium 2 small 3 small

cover
no yes yes

time (minutes)

4 small
5 medium 6 medium 7 medium

no
no yes yes

8 small
9 small 10 medium 11 medium

yes
no yes no

12 small

no
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Picture 4. Small pan, medium pan and glass cover

Picture 5. Medium pan with cover on stove

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

The results of experiment :

RunOrder pan size 1 medium 2 small 3 small 4 small 5 medium 6 medium cover no yes yes no no yes time (minutes) 3.92 3.07 3.00 3.53 3.63 3.83

7 medium
8 small 9 small 10 medium 11 medium 12 small

yes
yes no yes no no

3.20
3.22 3.75 3.98 3.50 3.60

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Minitab Output :
General Linear Model: time (minutes) versus pan size, cover Factor Type Levels Values pan size fixed 2 small, medium cover fixed 2 yes, no Analysis of Variance for time (minutes), using Adjusted SS for Tests Source DF Seq SS Adj SS Adj MS F P pan size 1 0.29768 0.29768 0.29768 4.90 0.058 cover 1 0.22141 0.22141 0.22141 3.65 0.093 pan size*cover 1 0.20021 0.20021 0.20021 3.30 0.107 Error 8 0.48560 0.48560 0.06070 Total 11 1.20489 S = 0.246374 R-Sq = 59.70% R-Sq(adj) = 44.58% Unusual Observations for time (minutes) time Obs (minutes) Fit SE Fit Residual St Resid 7 3.20000 3.67000 0.14224 -0.47000 -2.34 R R denotes an observation with a large standardized residu
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Main Effects Plot (data means) for time (minutes)

3.70 3.65 pan size cover

Mean of time (minutes)

3.60 3.55 3.50 3.45 3.40 3.35 small medium yes no

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Interpreting the Results :

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 rensponse suggests that small and cover (yes) give lower time to boil water .
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Case 3 : Painting experiment

We may want to investigate the influence of painting

methods (dipping, spray and brush) 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.
Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Our products :
Wooden toy train

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Picture 7. Materials and equipments of painting experiment

Picture 8. Preparation of experimental unit

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Picture 9. Dipping method for painting

Picture 10. Spraying method for painting

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

easy to learn, fun, challenging, and memorable.

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Picture 11. Drying

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

CONCLUSIONS
1.

2.

3.

This paper has shown the benefit of employing a systematic approach to simple experimentation using DOE, rather than utilising a trial and error approach The paper has also illustrated some simple experiments that can be used as a powerful teaching and learning tool in industrial statistics laboratoy. 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.

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University

Industrial Statistics Laboratory Industrial Engineering Department Trisakti University