DESIGN OF EXPERIMENTS WITH
SEVERAL FACTORS
Delivered to: CCIIDI, Ministry of Industry
By
Dr. Beteley Tekola (Assi. Professor)
Associate Director for Research, AAiT
School of Chemical and Bio Engineering
Addis Ababa Institute of Technology
FACTORIAL DESIGN
Many experiments involve the study of the effects of
two or more factors.
In general, factorial designs are most efficient for
this type of experiment.
By a factorial design, we mean that in each
complete trial or replication of the experiment all
possible combinations of the levels of the factors are
investigated.
For example, if there are a levels of factor A and b
levels of factor B, each replicate contains all ab
treatment combinations.
When factors are arranged in a factorial design,
they are often said to be crossed.
FACTORIAL EXPERIMENTS
If there are two factors A and B with a levels of factor
A and b levels of factor B, each replicate contains all ab
treatment combinations.
The effect of a factor is defined as the change in
response produced by a change in the level of the
factor.
It is called a main effect because it refers to the
primary factors in the study.
FACTORIAL EXPERIMENTS
This is a factorial experiment with two factors, A and B, each at
two levels (Alow, Ahigh, and Blow, Bhigh).
The main effect of factor A is the difference between the average
response at the high level of A and the average response at the
low level of A, or
That is, changing factor A from the low level to the high level
causes an average response increase of 20 units.
Similarly, the main effect of B is
FACTORIAL EXPERIMENTS
DESIGN OF EXPERIMENTS (DOE)
IN MANUFACTURING INDUSTRIES
Statistical methodology for systematically
investigating a system's input-output
relationship to achieve one of several goals:
Identify important design variables (screening)
Optimize product or process design
Achieve robust performance
Key technology in product and process
development
Used extensively in manufacturing industries
Part of basic training programs such as Six-sigma
DESIGN AND ANALYSIS OF EXPERIMENTS
A HISTORICAL OVERVIEW
Factorial and fractional factorial designs (1920+)
→ Agriculture
Sequential designs (1940+) → Defense
Response surface designs for process
optimization (1950+) → Chemical
Robust parameter design for variation reduction
(1970+)
→ Manufacturing and Quality Improvement
Virtual (computer) experiments using
computational models (1990+)
→ Automotive, Semiconductor, Aircraft, …
(FULL) FACTORIAL DESIGNS
All possible combinations
General: IxJxK…
Two-level designs: 2 x 2, 2 x 2 x 2, … →
(FULL) FACTORIAL DESIGNS
All possible combinations of the factor settings
Two-level designs: 2 x 2 x 2 …
General: I x J x K … combinations
Will focus on
two-level designs
OK in screening phase
i.e., identifying
important factors
(FULL) FACTORIAL DESIGNS
All possible combinations of the factor settings
Two-level designs: 2 x 2 x 2 …
General: I x J x K … combinations
Full Factorial Design
9.5
5.5
Algebra
-1 x -1 = +1
…
Design Matrix
Full Factorial Design
7
9+9+3+3 7+9+8+8
6 8
6 – 8 = -2
TWO FACTOR MODEL
The observations of a simplest two factor model may
be described by the linear statistical model
where µ is the overall mean effect,
τi is the effect of the i th level of factor A,
βj is the effect of the jth level of factor B,
(τβ)ij is the effect of the interaction between A and B, and
εijk is a random error component having a normal
distribution
TWO FACTOR MODEL
The analysis of variance (ANOVA), in particular,
will continue to be used as one of the primary tools for
statistical data analysis.
We are interested in testing the hypotheses of
no main effect for factor A,
no main effect for B, and
no AB interaction effect
EXAMPLE
ANOVA Table for a two-factorial, fixed effect model
EXAMPLE 1
Aircraft primer paints are applied to aluminum
surfaces by two methods: dipping and spraying. The
purpose of the primer is to improve paint adhesion,
and some parts can be primed using either
application method. The process engineering group
responsible for this operation is interested in
learning whether three different primers differ in
their adhesion properties.
A factorial experiment was performed to investigate
the effect of paint primer type and application
method on paint adhesion. For each combination of
primer type and application method, three specimens
were painted, then a finish paint was applied, and
the adhesion force was measured.
EXAMPLE
REGRESSION MODEL
Suppose that both of our design factors are
quantitative (such as temperature, pressure, time,
etc.), then a regression model representation of
the two-factor factorial experiment could be written
as
where y is the response, the B are parameters whose
values are to be determined, X1 is a variable that
represents factor A, X2 is a variable that represents
factor B, and E is a random error term, and X1X2
represents the interaction between X1 and X2
