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SIX SIGMA TOOL BOX - MATERIAL RESOURCES

| Material Resources | EVOPtimizer | Statistical Support | Quality America-Certification |

Obtain Process Target Optimization Question: 1. Open Study Guide / Exam 2. Path for Study Guide ONLY: Study Guide ---> Applications ---> Process Target Optimization Perform Screening DOE Analyze Main Effects ONLY: 3. Open Minitab 4. Stat ---> DOE ---> Factorial ---> Create Factorial Design a. Select Plackett-Burman design (only evaluates main effects) b. Click appropriate number of factors (= number of factors in problem) c. Click Designs ---> OK d. Click Factors ---> Enter low / high factor levels ---> OK e. Click Options ---> Deselect randomize runs ---> OK f. OK g. Copy DOE Matrix 5. Study Guide / Exam a. Click in first available cell in column A b. Paste DOE matrix (keystroke: Shift + Insert) c. Highlight first row of factor levels in copied matrix (this is not a required step but is helpful in visualizing what factor levels need to be entered into the cells) d. Type-in the factor levels from the matrix to their respective boxes on the left e. Compute response 8 times f. Repeat steps 5.c ---> 5.e for the remaining rows with factor levels in the spreadsheet g. Copy DOE matrix with responses (keystroke: Control + Insert) 6. Return to Minitab 7. Stat ---> DOE ---> Factorial ---> Create Factorial Design a. Select Plackett-Burman design b. Click appropriate number of factors (= number of factors in problem) c. Click Designs ---> Change replicates = 8 ---> OK d. Click Factors ---> Verify low / high factor levels ---> OK e. Click Options ---> Verify randomize runs is not selected ---> OK f. OK g. Highlight cells showing the DOE matrix plus one extra column h. Paste data to this highlighted section (this is the data that was copied from the Study Guide / Exam) i. Type-in "Response" at the top of the appropriate column (this is not a required step but is helpful) 8. Stat ---> DOE ---> Factorial ---> Analyze Factorial Design a. Click "Response" into the response section b. Click Terms ---> Verify all main effects are selected ---> OK c. Click Graphs ---> Select pareto ---> OK d. OK 9. Interpret Results and Identify Potentially Significant Main Effects Ho: Main Effect IS NOT Statistically Significant at 5% Ha: Main Effect IS Statistically Significant at 5% a. Use pareto chart b. Use the session window: if p < 0.05, then the factor is potentially significant NOTE: In this example, Both the pareto chart and the session window shows factors B, C, and E to be potentially significant. These factors will be used in the next screening DOE

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Results for: Worksheet Factorial Design Plackett-Burman Design Factors : 6 Replicates: 8 Runs: 64 Center pts (total): 0

Design: 8

Fractional Factorial Fit: Response versus A, B, C, D, E, F Estimated Effects and Coefficients for Response (coded units) Term Effect Coef SE Coef T P Constant -10956392 0.3783 -3E+07 0.000 A 0 0 0.3783 0.54 0.593 B -10798801 -5399401 0.3783 -1E+07 0.000 C 69001 34501 0.3783 9.1E+04 0.000 D -0 -0 0.3783 -0.29 0.774 E 240506 120253 0.3783 3.2E+05 0.000 F -0 -0 0.3783 -0.04 0.967 Analysis of Variance for Response (coded units) Source DF Seq SS Main Effects 6 1.86683E+15 Residual Error 57 522 Lack of Fit 1 7 Pure Error 56 515 Total 63 1.86683E+15 Unusual Observations for Response Obs 17 19 22 Response -16441550 -16441550 -16441550 Fit -16441544 -16441544 -16441544 SE Fit 1 1 1 Residual -6 -6 -6 St Resid -2.07R -2.07R -2.07R Adj SS 1.8668E+15 522 7 515 Adj MS F P 3.1114E+14 3E+13 0.000 9 7 0.75 0.390 9

R denotes an observation with a large standardized residual Estimated Coefficients for Response using data in uncoded units Term Coef Constant -10956392 A 0.000406250 B -10798.8 C 69.0014 D -0.000218750 E 240.506 F -0.000031250 Perform Second Screening DOE Analyze Interactions of Remaining Factors: Note: In production, it may be more efficient to skip the screening design. The initial simplex requires n+1 trials, and each additional step is a trial. It is often more efficient to begin with many factors and screen them out as the data is collected. 10. Stat ---> DOE ---> Factorial ---> Create Factorial Design a. Select 2-level factorial (default generators) b. Click Appropriate number of factors (= result in step 9) c. Click designs ---> Full factorial ---> OK d. Click Factors ---> Change name to reflect the factors identified in step 9 ---> verify low / high factor levels ---> OK

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e. Click Options ---> Verify randomize run is not selected ---> OK f. Copy DOE Matrix 11. Return to Study Guide / Exam a. Click in the next available cell in column A b. Paste DOE matrix (keystroke: Shift + Insert) c. Clear/delete contents in cells to the left for factors which are not significant to this problem d. Highlight first row of factor levels in new matrix e. Type-in the factor levels from the matrix to their respective boxes on the left (NOTE: ONLY include those factors that are potentially significant to this problem) f. Compute response 8 times g. Repeat steps 11.d ---> 11.f for the remaining rows with factor levels in the new matrix h. Copy new DOE matrix with responses (keystroke: Control + Insert) 12. Open Excel a. Paste data into Excel b. Delete columns with no factor level data (there will be zeros in these cells) c. Copy the modified Matrix with responses 13. Return to Minitab 14. Stat ---> DOE ---> Factorial ---> Create Factorial Design a. Select 2-level factorial (default generators) b. Click Appropriate number of factors (= result in step 9) c. Click Designs ---> Full factorial ---> Change Replicates = 8 ---> OK d. Click Factors ---> Change name to reflect the factors identified in step 9 ---> verify low / high factor levels ---> OK e. Click Options ---> Verify randomize run is not selected ---> OK f. Highlight cells showing the DOE matrix plus one extra column g. Paste data to this highlighted section (this is the data that was copied from Excel) h. Type-in "Response" at the top of the appropriate column 15. Stat ---> DOE ---> Factorial ---> Analyze Factorial Design a. Click "Response" into response section b. Click Terms ---> Remove the 3-way interaction from the "selected terms" ---> OK c. Click Graphs ---> Select pareto ---> OK d. OK 16. Interpret Results and Identify Potentially Significant Main Effects Ho: Main Effect IS NOT Statistically Significant at 5% Ha: Main Effect IS Statistically Significant at 5% NOTE: In this example, Both the pareto chart and the session window shows factors C and E are statistically significant. These factors will be used in the Response Surface DOE a. Use pareto chart b. Use the session window: if p < 0.05, then the factor is potentially significant

Factorial Design Full Factorial Design Base Design: 3, 8 Factors: 3 Runs: 64 Replicates: 8 Blocks: none Center pts (total): 0 All terms are free from aliasing Fractional Factorial Fit: Response versus B, C, E Estimated Effects and Coefficients for Response (coded units)

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Term Effect Constant -1 B -1 C 104753 E 204753 B*C -0 B*E -0 C*E 10793008

Coef 0953496 -0 52377 102377 -0 -0 5396504

SE Coef 0.1649 0.1649 0.1649 0.1649 0.1649 0.1649 0.1649

T -7E+07 -2.37 3.2E+05 6.2E+05 -0.47 -0.47 3.3E+07

P 0.000 0.021 0.000 0.000 0.637 0.637 0.000

Analysis of Variance for Response (coded units) Source DF Seq SS Adj SS Main Effects 3 8.46353E+11 8.4635E+11 2-Way Interactions 3 1.86382E+15 1.8638E+15 Residual Error 57 99 99 Lack of Fit 1 10 10 Pure Error 56 90 90 Total 63 1.86467E+15

Adj MS F P 2.8212E+11 2E+11 0.000 6.2127E+14 4E+14 0.000 2 10 5.95 0.018 2

Estimated Coefficients for Response using data in uncoded units Term Coef Constant -10953496 B -0.000781250 C 104.753 E 204.753 B*C -3.12500E-07 B*E -3.12500E-07 C*E 21.5860 Perform Response Surface Design to Begin Optimization of the Significant Factors: Response Surface methodology is designed to fit non-linear equations with multiple independent variables to a single response variable. Response Surface design is approximating the model bases on the data given and assumes the data can be fit to some sort of polynomial, which is not true in all cases. Therefore, Response Surface will assist in honing in on the optimal factors but will not always give the true optimum. 17. Stat ---> DOE ---> Response Surface ---> Create Response Surface Design a. Click Appropriate number of factors (= result in step 16) b. Click Designs ---> OK c. Click Factors ---> Change name to reflect the factors identified in step 16 ---> input low / high factor levels ---> OK (NOTE: start at 500 for the factor levels) d. Click Options ---> Deselect randomize runs ---> OK e. OK f. Copy Matrix 18. Return to Study Guide / Exam a. Click in the next available cell in column A b. Paste Response Surface matrix (keystroke: Shift + Insert) (NOTE: adjust column width to view complete data) c. Clear/delete contents in cells to the left for factors which are not significant to this problem d. Highlight first row of factor levels in new matrix e. Type-in the factor levels from the matrix to their respective boxes on the left (NOTE: ONLY include those factors that are significant to this problem. If the factor level generated in Minitab is outside of 500, then input 500. (e.g. If the generated factor level is 700, then input 500.)) f. Compute response (only one time each) g. Repeat steps 18.d ---> 18.f for the remaining rows with factor levels in the new matrix h. Copy responses only (keystroke: Control + Insert) 19. Return to Minitab 20. Paste responses in worksheet for Response Surface Design 21. Type-in "Response" at the top of the appropriate column 22. Stat ---> DOE ---> Response Surface ---> Analyze Response Surface Design a. Click "Response" into response section ---> Select "uncoded units" ---> OK b. Click Terms ---> Verify "Full Quadratic" is selected ---> OK c. OK 23. Stat ---> DOE ---> Response Surface ---> Contour / Surface (Wireframe) Plots a. Select both Contour plot and Surface (Wireframe) plot b. Click setup on each ---> OK (NOTE: nothing needs to be changed within the setup but you must select setup and click OK, otherwise it will not work) c. Click OK after going into setup for both plots

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24. Use the contour plot to hone in on the optimal factor levels. a. Using the highest contour plot, estimate the low/high factor levels b. Steps 17 through 24 may be repeated several times. Each time the response surface design is run, the spread between the low/high factor levels should be reduced. The goal is to hone in on the optimal factor levels, thus generating a better model in Minitab and reducing the number of Sequential Simplex Optimizations that will be run. NOTE: in the "real" world, the ratio of the number of Response Surface Designs vs. Sequential Simplex Optimizations would be reversed from this example. NOTE: ensure the maximum response is shown in the contour plot. If the center of the highest-level contour is off the plot, then rerun the Response Surface design with wider factor levels.

25. Stat ---> DOE ---> Response Surface ---> Response Optimizer a. Click "Response" to the selected section ---> OK b. Click Setup ---> Under "goal" click in the box and make the appropriate selection: i. i. If MAXIMIZE, enter lower value and target (e.g. Lower Value = Highest Contour & Target = 20,000 (estimate max) ii. ii. If MINIMIZE, enter target and upper value iii. iii. If TARGET, enter target value c. Click Options ---> OK (NOTE: nothing needs to be changed within the options but you must select options and click OK, otherwise it will not work) d. OK (NOTE: this may take a few minutes, please be patient) e. Record the optimized factor levels Sequential Simplex Optimization: Sequential Simplex Optimization is a method of steepest ascent. The simplex model is a geometric figure with the number of vertexes equal to the number of factors plus one. This is an iterative process, which will lead to the true optimum while also minimizing scrap and not interrupting production. This process will always lead to the true optimum because the model is not being approximated; the actual model is being used to generate the response. NOTE: for this section always use the coordinate values given in the spreadsheet and calculate the response in the Study Guide / Exam 26. Open the Sequential Simplex Optimization worksheet

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27. Choose n+1 starting points (where n is the number of significant factors, in this case it is 3 starting combinations since 2 factors are significant) for the Sequential Simplex Optimization and calculate the respective responses in the Study Guide / Exam NOTE: this example assumes a 2-factor design, therefore 3 vertexes are required 3 Starting Points: Begin the optimization by using the bottom left corner point from the contour plot generated in step 23, the optimized factor levels obtained in step 25, and a third point which makes a right triangle with the first two points 28. In EVOPtimzer: a. When the program opens it will have the Initialize Simplex Algorithm window open and ready for input.

b. Verify that the number of factors is 2 (according to finding 2 significant factors from your screening DOE) and that the problem type is set to Maximize the response.

29. Hit the Define Factors button. a. Define the Significant factors and their limits. Then click on Apply Changes.

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30. From the exam, calculate the responses from the three vertices i.e. Best (2.1,4.6); Next Best (2.1,-10); and Worst (-20,-10). Make sure to clear non significant factors.

31. In EVOPtimizer, click on the Define Initial Simplex button.

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32. In the Initial Simplex matrix, input the initial vertices and their respective responses, and then hit the Continue button.

33. After clicking continue, it will take you back to the Initial Simplex Algorithm screen. Then click on Begin Optimization.

34. Then the Simplex Optimization will begin by giving two levels to calculate a response.

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35. Calculate a response from the exam for the two factor levels.

36. Input the response in the Result box of the optimizer and click the Next Step button.

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37. The simplex Optimization window will continue to calculate levels for each factor. These levels are input into the exam question to calculate the response until the maximum levels are determined. This may take several iterations. As the points start to converge, the response value will change minimally. Also, the points will change minimally. It can be interpreted that the factor levels are at their optimal values.

38. Enter the optimized factor levels into the exam

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