PSL - Six Sigma Design of Experiments (DoE)

Uncontrollable Inputs/Noise
The Experimental Design Model
X1 X2 X3
Controllable Inputs
Z1 Z2 Z3
Inputs:
Raw Materials,
components, etc.
Y1, Y2, etc.
Quality
Characteristics/
Outputs LSL USL
LSL USL
The Process
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Design of Experiments
Responses Related to
Producing a Product
Performing a Service
Completing a Task
Planned changes in KPIV’s in order to observe corresponding changes in KPOV’s
Experimental Process
A Controlled Blending of Inputs
Which Generates Corresponding
Measurable Outputs
People
Material
Equipment
Methods
Environment

Simulation 2: The X Pult
Mission objective
The general has commanded your team to consistently hit the
enemy at a distance of 2.5 meters every time.
Exercise
Holding everything else constant, how do you expect the
variables to influence distance?
• Increased number of rubber bands.
• Increased launch angle
• Increased pull back angle
• Using a different type of ball
1. Based on the one variable at a time method, design the
variables value to hit the target at 2.5metres.
2. Using the set of specifications, launch 10 shots at the
target. How many of these shots were on target?
Use the templates and worksheet below to collate data.
Time allocated = 45 minutes
One Variable at a time Method

Recommended Reading and Resources
Books

Session Format
• Terminology
• Full factorial Design of Experiment
• Yates order
• Repeats/Replicates/Randomization
• Blocking
• Simulation 3: X Pult
• Workplace project

Standard Order of 2 Level Designs
• The design matrix for 2 level are shown in standard order :
– The low level is indicated by a “-” and the high level by a “+”
– This order is commonly referred to Yates standard order

4-Run DOE with Four Repeats
Response
Run y1 y2 y3 y4 Mean
1 2.3 2.7 2.4 2.4 2.45
2 2.8 3.0 2.9 2.8 2.88
3 3.6 3.4 3.6 3.5 3.53
4 3.0 3.2 3.2 3.1 3.13

Blocking
• Blocking is a way for us to protect ourselves
from certain noise factors
• We can block on natural variables in our
process, such as shift, day, week, operator,
shutdown, supplier, raw material, batch etc.
• By blocking on these, it prevents their effect
from showing up as an effect of another factor
• It also allows us to determine whether or not the
blocked factor affects our response

Tools and Templates
1. X Pult tally checklist
2. SIPOC Map
3. Design of Experiment planning template
4. Stakeholder analysis
5. X Pult Design of Experiment data collection
template
6. Design of Experiment Excel Statistic Pack

Session Format
• Design efficiency
• Fractional factorial
• Confounding
• Resolutions
• Simulation 4: X Pult
• Workplace project
• Project Guidelines
• Assessment criteria

Fractional Factorial Notation
• When we go to a fractional factorial design, we are
not able to estimate all of the interactions
• The amount that we are able to estimate is indicated
by the resolution of an experiment
• The higher the resolution, the more we can measure
Runs
p
k
R #
2 

 2 is the number of levels for each factor
 k is the number of factors to be investigated
 2-p is the size of the fraction (p = 1 ® 1/2 fraction, p = 2 ®
1/4 fraction, etc.)
 2k-p is the number of runs
 R is the resolution

Resolution
• Resolution is typically measured as III or higher, with the higher number indicating
less significant aliasing.
• If interactions are significant, we need to be careful about how we use resolution.

Simulation 4: The X Pult
Mission objective
To find the optimum setting in order to hit the enemies constantly
and accurately at 2.5 meters.
Exercise
1. Generate Yates Order for a Fractional Factorial DOE design for
your X pult.
2. Repeat, replicate and randomize your design. Generate the
data collection checklist.
3. Using the generated design conduct your experiment.
4. Use the DOE statistic pack template and identify the optimum
setting to hit the target at 2.5 meters.
5. Take 10 shots using the optimized setting. What is the
accuracy rate?
Time allocated = 90 minutes
Fractional Factorial Design

Project Guidelines
Use the required competencies below as a
checklist for your Process Optimization project.
To successfully complete this unit of
competency, you should ensure that you
document as many activities as possible using
the templates provided.
Your coach will guide you through the process.

Wrap Up
• Participants identify one key item that they
will remember from today’s session
• Don’t forget to bring your project
information to the next session for review
and assessment
• Good luck – go make a difference

1
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PSL - Six Sigma Design of Experiments (DoE)

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