經(jīng)典六西格瑪(6 sigma)培訓(xùn)內(nèi)部資料I 01-Intr

1、1Introduction to ExperimentationI 階段目錄1.Introduction to Experimentation 實(shí)驗(yàn)設(shè)計(jì)簡(jiǎn)介2.Introduction To 2k Factorial Experiment 2k 因子實(shí)驗(yàn)設(shè)計(jì)簡(jiǎn)介3.Fractional Factorials Designs 部分因子設(shè)計(jì)4.Taguchi DOE 田口DOE5.I Phase Roadmap I 階段路徑圖Introduction to Experimentation 實(shí)驗(yàn)設(shè)計(jì)簡(jiǎn)介3Introduction to ExperimentationThe purpose of an

2、 experiment is to better understand the real world, not to understand the experimental data 進(jìn)行一個(gè)實(shí)驗(yàn)的目的是為了更好的了解真實(shí)的世界,而不是了解實(shí)驗(yàn)數(shù)據(jù)。William DiamondIBM -Retired Statistician IBM -已退休的統(tǒng)計(jì)員4Introduction to ExperimentationLearning Objectives 學(xué)習(xí)目的a Explain what DOE is.解釋什么是DOE.a Understand why use Experiment Des

3、ign 理解為什么使用DOE a Explain some terminology of DOE. 解釋一些DOE 的術(shù)語(yǔ)a Describe steps of DOE描述DOE 的基本步驟a Describe the barriers to effective DOE 描述有效實(shí)驗(yàn)設(shè)計(jì)的一些阻礙a Understand the Limitation of OFAT 了解OFAT 實(shí)驗(yàn)設(shè)計(jì)的局限性.Upon completion of this chapter, the participants will be able to 結(jié)束對(duì)本章的學(xué)習(xí)后,學(xué)員將能夠5Introduction to E

4、xperimentationWhat is Design of Experiments(DOE 什么是實(shí)驗(yàn)設(shè)計(jì)DOE consists of purposeful changes of input variables (Factors to a process (or activity in order to observe the corresponding changes in the output variables (Responses.試驗(yàn)設(shè)計(jì)通過(guò)有目的地改變一個(gè)過(guò)程(或活動(dòng)的輸入變量(因子,以觀察輸出變量(響應(yīng)量的相應(yīng)變化.It is a scientific approach w

5、hich allows the researcher to gain knowledge in order to better understand a process and to determine how the inputs (factors affect the output, or response(s.它是一種科學(xué)的方法,使研究者更好地了解一個(gè)過(guò)程并確定輸入(因子是如何影響輸出(響應(yīng)量。6Introduction to ExperimentationWhat is Design of Experiments(DOE 什么是實(shí)驗(yàn)設(shè)計(jì)Product產(chǎn)品Or或者Process過(guò)程Fac

6、tors 因子(controlled variables 可控制的變量X 1X 2:X nResponse響應(yīng)變量(measured outcome 可測(cè)量的輸出YNoise 噪音(uncontrolled variables非可控制變量 NID(0 , Y = Y +7Introduction to ExperimentationWhy Use DOE.為什么使用試驗(yàn)設(shè)計(jì)It is the most effective method for identifying the key input variables (Factors.試驗(yàn)設(shè)計(jì)是識(shí)別關(guān)鍵輸入因子的最有效方法。It is the m

7、ost efficient way to gain an understanding of the relationship between the input factors and response(s.試驗(yàn)設(shè)計(jì)是幫助我們了解輸入因子和響應(yīng)變量關(guān)系的最高效途徑.It is a method for build a mathematical model relating the response to the input factors.試驗(yàn)設(shè)計(jì)是建立響應(yīng)變量與輸入因子之間的數(shù)學(xué)關(guān)系模型的方法.8Introduction to ExperimentationWhy Use DOE.為什么使用

8、試驗(yàn)設(shè)計(jì)It is a means of determining the settings of the input factorswhich optimize the responseand minimize costs.試驗(yàn)設(shè)計(jì)是確定優(yōu)化輸出并減少成本的輸入設(shè)定值的途徑.It is a scientific method forsetting tolerance.試驗(yàn)設(shè)計(jì)是設(shè)定公差的科學(xué)方法.9Introduction to ExperimentationBenefit of DOE實(shí)驗(yàn)設(shè)計(jì)的益處The benefits of DOE are:實(shí)驗(yàn)設(shè)計(jì)的益處如下aProcess perfo

9、rmance improvement改善過(guò)程績(jī)效水平。bCosts reduction降低成本.cShortening product development and production time.縮短產(chǎn)品開(kāi)發(fā)時(shí)間和生產(chǎn)時(shí)間.10Introduction to ExperimentationBasic Terminology基本術(shù)語(yǔ)Response 響應(yīng)變量a measurable outcome of interest, e.g. yield, strength, etc所關(guān)注的可測(cè)量的輸出結(jié)果,如良率、強(qiáng)度等。Factors 因子controllable variables that a

10、re deliberately manipulated todetermine their individual and joint effects on the response(s,e.g.temperature, time, etc可控的變量,通過(guò)有意的變動(dòng),可確定其對(duì)響應(yīng)變量的影響,如溫度、時(shí)間等。11Introduction to ExperimentationBasic Terminology基本術(shù)語(yǔ)Level 水平a value or setting of a factor,因子的取值或設(shè)定,如:e.g. Level 1 for time = 2 hr 舉例:時(shí)間因子的水平1=2

11、小時(shí)Level 2 for time = 3 hr 時(shí)間因子的水平2=3小時(shí)Treatment 處理(組合a set of specified factor levels for an experimental run某次實(shí)驗(yàn)的整套因子e.g. Treatment 1: time = 2 hr and temperature = 175CTreatment 2: time = 3 hr and temperature = 225C 舉例:處理1:時(shí)間=2小時(shí),溫度=175處理2:時(shí)間=3小時(shí),溫度=22512Introduction to ExperimentationBasic Termin

12、ology基本術(shù)語(yǔ)Repetition重復(fù)means that all of the data for a test combination is collected without resetting the run.重復(fù)指在不重新組合實(shí)驗(yàn)設(shè)定的情況下,連續(xù)進(jìn)行實(shí)驗(yàn)并收集數(shù)據(jù)。Replication復(fù)制means that each data value is collected after resetting the test combination.復(fù)制意謂每個(gè)數(shù)據(jù)值在重新設(shè)定測(cè)試組合之后收集。13Introduction to ExperimentationBasic Terminol

13、ogy 基本術(shù)語(yǔ)Randomization 隨機(jī)化Refers to sequence in which every run has an equalchance of being selected for a particular position適當(dāng)安排實(shí)驗(yàn)次序,使每個(gè)實(shí)施被選出的機(jī)會(huì)都相等14Introduction to ExperimentationSteps of DOE 實(shí)驗(yàn)設(shè)計(jì)步驟I.Statement of the problem陳述問(wèn)題II.Set the objective of the DOE 設(shè)立目標(biāo)III.Determine the output response(

14、s確定輸出變量(盡量用計(jì)量型數(shù)據(jù)IV.Identify input factors (control factors and noise factors識(shí)別輸入因子(可控因子/噪聲因子V.Select the levels for each factors選定每個(gè)因子的水平.改善階段開(kāi)始(一般I 階段開(kāi)始DOE 15Introduction to ExperimentationVI.Select the type of DOE選擇實(shí)驗(yàn)設(shè)計(jì)類(lèi)型用MINTABVII.Plan and prepare the resource for conducting theexperiments計(jì)劃并為實(shí)施實(shí)

15、驗(yàn)做準(zhǔn)備.VIII.Conduct the experiments and record the data實(shí)施實(shí)驗(yàn)并記錄數(shù)據(jù).IX.Analyze the data and draw conclusion.分析數(shù)據(jù)并得出結(jié)論.-用MINTAB X.Run confirmatory experiments, if necessary.必要時(shí)進(jìn)行確認(rèn)實(shí)驗(yàn).Steps of DOE 實(shí)驗(yàn)設(shè)計(jì)步驟16Introduction to ExperimentationStep III: Determine the Response(s 步驟三: 確定響應(yīng)變量Use continuous responses

16、whenever possible盡量使用連續(xù)數(shù)據(jù)作輸出變量.-Continuous data provide more information 連續(xù)數(shù)據(jù)提供更多的信息.-Attribute data needs larger sample size 計(jì)數(shù)型數(shù)據(jù)需要大樣本量.Use response which can be measured precisely, accurately, andwith stability.盡量使用可精確,穩(wěn)定測(cè)量的輸出變量.17Introduction to ExperimentationStep IV: Identify Input Factors 步驟四

17、: 識(shí)別輸入因子Generally, input factors can be identified through:通?？赏ㄟ^(guò)以下工具識(shí)別輸入因子:-Fishbone diagram 魚(yú)骨圖-C&E matrix 因果矩陣-FMEA潛在失效模式及效果分析18Introduction to ExperimentationControl Factors vs. Noise Factors 可控因子與噪聲因子Controllable (Control factors are factors for which we can set and maintain a desired level duri

18、ng a process normal operation.可控(控制 因子是我們?cè)诠ば虻恼２僮鲿r(shí)能設(shè)定并且維持在期望水平的因子。Noise factors are factors that vary during normaloperation, and we cannot control them. Or, we prefer not to control them because doing so would be very expensive 。噪音因子是在正常的操作期間變化的因子,而且我們不能夠控制他們;或者我們寧愿不控制他們,因?yàn)檫@麼做會(huì)很昂貴。19Introduction to

19、 ExperimentationStep V: Select Levels for Each Factor 步驟五: 選擇輸入因子的水平Levels can be either quantitative or qualitative.因子水平可以是定量的,也可是定性的.Quantitative example-定量舉例Temperature at 100 C vs. 120C 溫度:100 和120 Pressure at 20 psi vs. 25 psi 壓力:20 psi 和25 psi Rotation at 3000RPM vs. 3500RPM 旋轉(zhuǎn)度:3000RPM vs. 35

20、00RPM Qualitative example-定性舉例Machine A vs. Machine B 機(jī)器A 和機(jī)器B Shift A, B, C曲線(xiàn)A 、B 、C Material type: New vs old材料類(lèi)型:新和舊20Introduction to ExperimentationStep V: Select levels for each factor 步驟五: 選擇輸入因子的水平Levels are selected based on DOE objective.因子水平的選擇是基于實(shí)驗(yàn)?zāi)康?Objective #1: Determine vital few inpu

21、ts from a large numberof variables (Screening目標(biāo)1 :從大量的變量中確定出重要的少數(shù)輸入因子(篩選Set “Bold”levels at extremes of current capabilities 將當(dāng)前能力的極限值設(shè)定為“大膽”水準(zhǔn)21Introduction to ExperimentationStep V: Select levels for each factor 步驟五: 選擇輸入因子的水平Objective #2: To understand factor relationships andinteractions目標(biāo)#2:了解因

22、素關(guān)系及交互作用Once critical inputs are identified, reduced spacing of the levels is used to identify interactions among Inputs一旦確定重要的輸入因子,通過(guò)減小水平間距來(lái)確定輸入因子間的交互作用Objective #3: To identify the operating window of a set ofinput variables (Process Optimization目標(biāo)#3:確定一組輸入變量的操作窗口(過(guò)程最優(yōu)化Close settings are again use

23、d 水平設(shè)定進(jìn)一步接近22Introduction to ExperimentationStep VI: Select the type of DOE 步驟六: 選擇DOE 類(lèi)型5 or more 5個(gè)或更多To find the factor levels that provide the best results發(fā)現(xiàn)提供最好結(jié)果的因子和水平To build a math model(evaluates some interactions建立數(shù)學(xué)模型(評(píng)價(jià)部分交互作用FractionalFactorial 部分因子法4 or fewer 4或更少To find the factor leve

24、ls that provide the best results.發(fā)現(xiàn)提供最好結(jié)果的因子和水平To build a math model (evaluates all interactions建立數(shù)學(xué)模型(可評(píng)價(jià)所有交互作用Full Factorial 全因子實(shí)驗(yàn)法Typical Number of Controllable Factors 可控因子的多少Objectives 目的Common Types 實(shí)驗(yàn)的常用類(lèi)型23Introduction to ExperimentationStep VI: Select the type of DOE 步驟六: 選擇DOE 類(lèi)型3 or more

25、3或更多Optimization 最優(yōu)化To build a math model when non-linear effects arepresent (Response Surface Methodology is often used當(dāng)存在非線(xiàn)性影響時(shí)建立數(shù)學(xué)模型(經(jīng)常使用響應(yīng)曲面方法Central Composite Design (CCD, or Box-Behnken 中心合成法或Box-Behnken7 or more 7個(gè)或更多(evaluates no interactions(不評(píng)價(jià)交互作用Screening 篩選法Typical Number of Controllabl

26、e Factors 可控因子的多少Objectives 目的Common Types 實(shí)驗(yàn)的常用類(lèi)型24Introduction to ExperimentationStep VII: Plan conducting the experiment 步驟七: 實(shí)施實(shí)驗(yàn)的計(jì)劃Planning for conducting the experiments should address the following questions:實(shí)施實(shí)驗(yàn)的計(jì)劃應(yīng)解決以下問(wèn)題: What will it cost?費(fèi)用如何?Have we talked to internal customers about thi

27、s?我們已經(jīng)與內(nèi)部客戶(hù)討論過(guò)嗎? How long will it take?需要多長(zhǎng)時(shí)間?Is a pilot run necessary?有必要做試運(yùn)行嗎?Do we need a proposal and permission?我們需要提案及許可嗎? Who will run the experiment?誰(shuí)來(lái)進(jìn)行實(shí)驗(yàn)?25Introduction to ExperimentationStep VIII & IX: Conduct experiments, Obtain data and analyze data步驟八和九: 實(shí)施實(shí)驗(yàn),獲取數(shù)據(jù)并分析數(shù)據(jù)Obtain the data 獲

28、取數(shù)據(jù)-Validate the data collection and data values 確認(rèn)數(shù)據(jù)收集與數(shù)據(jù)值-Validate that special conditions did not influence 確認(rèn)特別情況不會(huì)產(chǎn)生影響Analyze the data using Minitab 用Minitab 分析數(shù)據(jù)We will cover this in later modules.我們將在接下來(lái)的課程里講解.26Introduction to ExperimentationBarriers to Effective DOE 實(shí)施實(shí)驗(yàn)的阻礙Problem not clear

29、 問(wèn)題不清Objectives not clear 目標(biāo)不明Inadequate brainstorming集體討論不充分Results of the experiment unclear 實(shí)驗(yàn)結(jié)果不清DOE is too costly實(shí)驗(yàn)設(shè)計(jì)費(fèi)用過(guò)高DOE is too time consuming實(shí)驗(yàn)設(shè)計(jì)耗時(shí)過(guò)長(zhǎng)Lack of understanding DOE strategies 對(duì)實(shí)驗(yàn)設(shè)計(jì)策略缺乏理解27Introduction to ExperimentationBarriers to Effective DOE 實(shí)施實(shí)驗(yàn)的阻礙Not confident during the early stages 實(shí)驗(yàn)初