Design of experiments, piloting solutions, control plans, and statistical process control used in the Improve and Control phases.
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- What is the primary purpose of Design of Experiments?
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To systematically vary input factors and study their effects on an output variable to identify the vital few factors influencing the response.- In DOE, what is a factor?
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An input variable that is deliberately changed or manipulated during an experiment to study its effect on the response.- In DOE, what are levels?
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The different values or settings of a factor being tested in an experiment (e.g., temperature at 150°C, 200°C, and 250°C).- What is a full factorial design?
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An experiment testing every possible combination of all factor levels (e.g., 2^3 = 8 runs for three factors at two levels each).- What is a fractional factorial design?
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A DOE using a subset of all possible factor combinations to reduce experimental runs while still identifying main effects.- What does resolution mean in fractional factorial designs?
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The ability to distinguish between main effects and interaction effects; higher resolution (III, IV, V) provides better separation of effects.- Distinguish between a main effect and an interaction effect in DOE.
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A main effect is how one factor alone affects the response; an interaction occurs when two factors together produce an effect different from their individual effects.- What is blocking in DOE?
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Grouping experimental runs to minimize the effect of known nuisance variables that cannot be directly controlled.- What is confounding in DOE?
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When the effect of one factor becomes entangled with another factor, making it impossible to separate their individual contributions to the response.- What is Response Surface Methodology?
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A DOE technique using polynomial regression to map the relationship between factors and response over a region of interest, often to optimize the response.- What is the purpose of center points in fractional factorial or response surface designs?
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To detect curvature in the response surface and provide an estimate of pure error independent of the fitted model.- Why is randomization important in the run order of a DOE?
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To prevent bias from time-related factors and ensure observed effects are due to the factors studied, not confounding variables that change over time.- What is a pilot run in Six Sigma?
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A small-scale trial of a proposed solution to verify feasibility, refine implementation details, and gather data before full deployment.- What must be validated before conducting a pilot run?
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The measurement system must be validated through a Gage R&R study to ensure it can accurately capture the effect of the proposed solution.- What is the purpose of a run chart during the pilot phase?
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To track the response variable over time during the pilot to detect shifts or trends and confirm the solution produces the desired effect.
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