Robust parameter design: Optimization of combined array approach with orthogonal arrays

Robust parameter design, originally proposed by Taguchi (1987. System of Experimental Design, vols. I and II. UNIPUB, New York), is an off-line production technique for reducing variation and improving a product's quality by using product arrays. However, the use of product arrays results in an exorbitant number of runs. To overcome the drawbacks of the product array several scientists proposed the use of combined arrays, where the control and noise factors are combined in a single array. In this paper, we use certain orthogonal arrays that are embedded into Hadamard matrices as combined arrays, in order to identify a model that contains all the main effects (control and noise) and their control-by-noise interactions with high efficiency. Aliasing of effects in each case is also discussed.     

Some robust parameter designs from orthogonal arrays

Robust parameter design, originally proposed by Taguchi [System of Experimental Design, Vols. I and II, UNIPUB, New York, 1987], is an offline production technique for reducing variation and improving a product's quality by using product arrays. However, the use of the product arrays results in an exorbitant number of runs. To overcome this drawback, several scientists proposed the use of combined arrays, where the control and noise factors are combined in a single array. In this paper, we use non-isomorphic orthogonal arrays as combined arrays, in order to identify a model that contains all the main effects (control and noise), their control-by-noise interactions and their control-by-control interactions with high efficiency. Some cases where the control-by-control-noise are of interest are also considered.     

Split-plot designs for robust product experimentation

Genichi Taguchi has emphasized the use of designed experiments in several novel and important applications. In this paper we focus on the use of statistical experimental designs in designingproducts to be robust to environmental conditions. The engineering concept of robust product design is very important because it is frequently impossible or prohibitively expensive to control or eliminate variation resulting from environmental conditions. Robust product design enablesthe experimenter to discover how to modify the design of the product to minimize the effect dueto variation from environmental sources. In experiments of this kind, Taguchi's total experimental arrangement consists of a cross-product of two experimental designs:an inner array containing the design factors and an outer array containing the environmental factors. Except in situations where both these arrays are small, this arrangement may involve a prohibitively large amount of experimental work. One of the objectives of this paper is to show how this amount of work can be reduced. In this paper we investigate the applicability of split-plot designs for thisparticular experimental situation. Consideration of the efficiency of split-plot designs and anexamination of several variants of split-plot designs indicates that experiments conductedin a split-plot mode can be of tremendous value in robust product design since they not only enable the contrasts of interest to be estimated efficiently but also the experiments can be considerably easier to conduct than the designs proposed by Taguchi.     

An orthogonal arrays approach to robust parameter designs methodology

Robust parameter design methodology was originally introduced by Taguchi [14 Taguchi, G. 1986. Introduction to Quality Engineering: Designing Quality Into Products and Process, Tokyo: Asian Productivity Organization.  [Google Scholar]] as an engineering methodology for quality improvement of products and processes. A robust design of a system is one in which two different types of factors are varied; control factors and noise factors. Control factors are variables with levels that are adjustable, whereas noise factors are variables with levels that are hard or impossible to control during normal conditions, such as environmental conditions and raw-material properties. Robust parameter design aims at the reduction of process variation by properly selecting the levels of control factors so that the process becomes insensitive to changes in noise factors. Taguchi [14 Taguchi, G. 1986. Introduction to Quality Engineering: Designing Quality Into Products and Process, Tokyo: Asian Productivity Organization.  [Google Scholar] 15 Taguchi, G. 1987. System of Experimental Design, Vol. I and II, New York: UNIPUB.  [Google Scholar]] proposed the use of crossed arrays (inner–outer arrays) for robust parameter design. A crossed array is the cross-product of an orthogonal array (OA) involving control factors (inner array) and an OA involving noise factors (outer array). Objecting to the run size and the flexibility of crossed arrays, several authors combined control and noise factors in a single design matrix, which is called a combined array, instead of crossed arrays. In this framework, we present the use of OAs in Taguchi's methodology as a useful tool for designing robust parameter designs with economical run size.     

Catalogue of Group Structures for Three-level Fractional Factorial Designs

Taguchi (1959) introduced the concept of split-unit design to sort the factors into different groups depending upon the difficulties involved in changing the levels of factors. Li et al. (1991) renamed it as split-plot design. Chen et al. (1993) have given a catalogue of small designs for two- and three-level fractional factorial designs pertaining to a single type of factors. Aggarwal et al. (1997) have given a catalogue of group structure for two-level fractional factorial designs developed under the concept of split-plot design. In this paper, an algorithm has been developed for generating group structure and possible allocations for various 3^n-k fractional factorial designs.     

Response model analysis for robust design experiments

Taguchi's robust design technique, also known as parameter design, focuses on making product and process designs insensitive (i.e., robust) to hard to control variations. In some applications, however, his approach of modeling expected loss and the resulting “product array” experimental format leads to unnecessarily expensive and less informative experiments. The response model approach to robust design proposed by Welch, Ku, Yang, and Sacks (1990), Box and Jones (1990), Lucas (1989), and Shoemaker, Tsui and Wu (1991) offers more flexibility and economy in experiment planning and more informative modeling. This paper develops a formal basis for the graphical data-analytic approach presented in Shoemaker et al. In particular, we decompose overall response variation into components representing the variability contributed by each noise factor, and show when this decomposition allows us to use individual control-by-noise interaction plots to minimize response variation. We then generalize the control-by-noise interaction plots to extend their usefulness, and develop a formal analysis strategy using these plots to minimize response variation.     

The A-optimal non-saturated weighing designs for n = 15 observations

The problem of constructing A-optimal weighing and first order fractional factorial designs for n ≡ 3 mod 4 observations is considered. The non-existence of the weighing design matrices for n = 15 observations and k = 13, 14 factors, for which the corresponding information matrices have inverses with minimum trace, is proved. These designs are the first non-saturated cases (k < n) in which the unattainability of Sathe and Shenoy's (1989) lower bound on A-optimality is shown. Using an algorithm proposed in Farmakis (1991) we construct 15 × k (+1, −1)-matrices for k = 13, 14 and we prove their A-optimality using the improved (higher) lower bounds on A-optimality established by Chadjiconstantinidis and Kounias (1994). Also the A-optimal designs for n = 15, k ⩽ 12 are given.     

Taguchi methods: linear graphs of high resolution

An important reason behind the success of the Taguchi methodology in qual- ity assurance has been the use of statistical methods, presented in a way that is accessible to the nonexpert user. Among the tools used to simplify the sta- tistical design of experiments has been the linear graph, apparently introduced by Taguchi. However, he did not consider the resolution of the corresponding designs (the higher the resolution, the more accurate the conclusions). For example, it will be shown that half of the linear graphs given by Taguchi for the L₁₆(2¹⁵) orthogonal array correspond to designs of resolution III, when designs of resolution IV are available (with the same lines in the linear graphs but with different assignments to the columns of the orthogonal array). A nontraditional but very straightforward method is presented for obtaining the alias chains and the linear graphs corresponding to an orthogonal array. The procedure can be easily understood and employed by nonstatisticians to find an experimental design of the highest possible resolution. The design can be used to obtain products or processes that are robust to variation.     

Saturated main-effect designs for factorial experiments

The results of a computer search for saturated designs for 2ⁿ factorial experiments with n runs is reported, (where n = 2 mod 4). A complete search of the design space is avoided by focussing on designs constructed from cyclic generators. A method of searching quickly for the best generators is given. The resulting designs are as good as, and sometimes better than, designs obtained via search algorithms reported in the literature. The addition of a further factor having three levels is also considered. Here, too, a complete search is avoided by restricting attention to the most efficient part of the design space under p-efficiency.     

Some resolvable orthogonal arrays with two symbols

A method of constructing a resolvable orthogonal array (4λk2,2) which can be partitioned into λ orthogonal arrays (4,k 2,1) is proposed. The number of constraints kfor this type of orthogonal array is at most 3λ. When λ=2 or a multiple of 4, an orthogonal array with the maximum number of constraints of 3λ can be constructed. When λ=4n+2(n≧1) an orthogonal array with 2λ+2 constraints can be constructed. When λ is an odd number, orthogonal arrays can be constructed for λ=3,5,7, and 9 with k=4,8,12, and 13 respectively.     

Catalogue of group structures for two-level fractional factorial designs

SUMMARY Taguchi introduced the concept of split-unit design to sort factors into different groups with respect to difficulties involved in changing the levels of factors. Li et al. have developed all possible group structures for eight factors in an L16 orthogonal array for resolution IV with split-plot design. Chen et al. have searched for a best design, according to the various criteria for two-level fractional factorial design and have presented a catalogue. In this paper, we have developed an algorithm for generating group structure and possible allocations for various 2n- k fractional factorial designs that correspond to the designs given by Chen et al.     

Comparisons of search designs using search probabilities

Search designs are considered for searching and estimating one nonzero interaction from the two and three factor interactions under the search linear model. We compare three 12-run search designs D1, D2, and D3, and three 11-run search designs D4, D5, and D6, for a 2⁴ factorial experiment. Designs D2 and D3 are orthogonal arrays of strength 2, D1 and D4 are balanced arrays of full strength, D5 is a balanced array of strength 2, and D6 is obtained from D3 by deleting the duplicate run. Designs D4 and D5 are also obtained by deleting a run from D1 and D2, respectively. Balanced arrays and orthogonal arrays are commonly used factorial designs in scientific experiments. “Search probabilities” are calculated for the comparison of search designs. Three criteria based on search probabilities are presented to determine the design which is most likely to identify the nonzero interaction. The calculation of these search probabilities depends on an unknown parameter ρ which has a signal-to-noise ratio form. For a given value of ρ, Criteria I and II are newly proposed in this paper and Criteria III is given in Shirakura et al. (Ann. Statist. 24 (6) (1996) 2560). We generalize Criteria I–III for all values of ρ so that the comparison of search designs can be made without requiring a specific value of ρ. We have developed simplified methods for comparing designs under these three criteria for all values of ρ. We demonstrate, under all three criteria, that the balanced array D1 is more likely to identify the nonzero interaction than the orthogonal arrays D2 and D3, and the design D4 is more likely to identify the nonzero interaction than the designs D5 and D6.The methods of comparing designs developed in this paper are applicable to other factorial experiments for searching one nonzero interaction of any order.     

Two-level minimum aberration designs in N =2 (mod 4) runs

For two-level factorials, we consider designs in N=2 (mod 4) runs as obtained by adding two runs, with a certain coincidence pattern, to an orthogonal array of strength two. These designs are known to be optimal main effect plans in a very broad sense in the absence of interactions. Among them, we explore the ones having minimum aberration, with a view to ensuring maximum model robustness even when interactions are possibly present. This is done by sequentially minimizing a measure of the bias caused by interactions of successively higher orders.     

Optimal orthogonal-array-based latin hypercubes

The use of optimal orthogonal array latin hypercube designs is proposed. Orthogonal arrays were proposed for constructing latin hypercube designs by Tang (1993). Such designs generally have better space filling properties than random latin hypercube designs. Even so, these designs do not necessarily fill the space particularly well. As a result, we consider orthogonal-array-based latin hypercube designs that try to achieve optimality in some sense. Optimization is performed by adapting strategies found in Morris & Mitchell (1995) and Ye et al. (2000). The strategies here search only orthogonal-array-based latin hypercube designs and, as a result, optimal designs are found in a more efficient fashion. The designs found are in general agreement with existing optimal designs reported elsewhere.     

Space-filling orthogonal arrays of strength two

This paper considers the use of orthogonal arrays of strength two as experimental designs for fitting a surrogate model. Contrary to standard space-filling designs or Latin hypercube designs, the points of an orthogonal array of strength two are well distributed when they are projected on the two-dimensional faces of the unit cube. The aim is to determine if this property allows one to fit an accurate surrogate model when the computer response is governed by second-order interactions of some input variables. The first part of the paper is devoted to the construction of orthogonal arrays with space-filling properties. In the second part, orthogonal arrays are compared with standard designs for fitting a Gaussian process model.     

Mixture designs with orthogonal blocks

Constructions of blocked mixture designs are considered in situations where BLUEs of the block effect contrasts are orthogonal to the BLUEs of the regression coefficients. Orthogonal arrays (OA), Balanced Arrays (BAs), incidence matrices of balanced incomplete block designs (BIBDs), and partially balanced incomplete block designs (PBIBDs) are used. Designs with equal and unequal block sizes are considered. Also both cases where the constants involved in the orthogonality conditions depend and do not depend on the factors have been taken into account. Some standard (already available) designs can be obtained as particular cases of the designs proposed here.     

A general method of constructing E(s2)-optimal supersaturated designs

There has been much recent interest in supersaturated designs and their application in factor screening experiments. Supersaturated designs have mainly been constructed by using the E ( s ²)-optimality criterion originally proposed by Booth and Cox in 1962. However, until now E ( s ²)-optimal designs have only been established with certainty for n experimental runs when the number of factors m is a multiple of n-1 , and in adjacent cases where m = q ( n -1) + r (| r | 2, q an integer). A method of constructing E ( s ²)-optimal designs is presented which allows a reasonably complete solution to be found for various numbers of runs n including n ,=8 12, 16, 20, 24, 32, 40, 48, 64.     

Optimum covariate designs in partially balanced incomplete block (PBIB) design set-ups

The use of covariates in block designs is necessary when the covariates cannot be controlled like the blocking factor in the experiment. In this paper, we consider the situation where there is some flexibility for selection in the values of the covariates. The choice of values of the covariates for a given block design attaining minimum variance for estimation of each of the parameters has attracted attention in recent times. Optimum covariate designs in simple set-ups such as completely randomised design (CRD), randomised block design (RBD) and some series of balanced incomplete block design (BIBD) have already been considered. In this paper, optimum covariate designs have been considered for the more complex set-ups of different partially balanced incomplete block (PBIB) designs, which are popular among practitioners. The optimum covariate designs depend much on the methods of construction of the basic PBIB designs. Different combinatorial arrangements and tools such as orthogonal arrays, Hadamard matrices and different kinds of products of matrices viz. Khatri–Rao product, Kronecker product have been conveniently used to construct optimum covariate designs with as many covariates as possible.     

Mean squared error of prediction approach to the analysis of a combined array

SUMMARY The combined array provides a powerful, more statistically rigorous alternative to Taguchi's crossed-array approach to robust parameter design. The combined array assumes a single linear model in the control and the noise factors. One may then find conditions for the control factors which will minimize an appropriate loss function that involves the noise factors. The most appropriate loss function is often simply the resulting process variance, recognizing that the noise factors are actually random effects in the process. Because the major focus of such an experiment is to optimize the estimated process variance, it is vital to understand the resulting prediction properties. This paper develops the mean squared error for the estimated process variance for the combined array approach, under the assumption that the model is correctly specified. Specific combined arrays are compared for robustness. A practical example outlines how this approach may be used to select appropriate combined arrays within a particular experimental situation.     

Pairwise orthogonal F-rectangle designs

The concept of pairwise orthogonal Latin square design is applied to r row by c column experiment designs which are called pairwise orthogonal F-rectangle designs. These designs are useful in designing successive and/or simulataneous experiments on the same set of rc experimental units, in constructing codes, and in constructing orthogonal arrays. A pair of orthogonal F-rectangle designs exists for any set of v treatment (symbols), whereas no pair of orthogonal Latin square designs of order two and six exists; one of the two construction methods presented does not rely on any previous knowledge about the existence of a pair of orthogonal Latin square designs, whereas the second one does. It is shown how to extend the methods to r=pv row by c=qv column designs and how to obtain t pairwise orthogonal F-rectangle design. When the maximum possible number of pairwise orthogonal F-rectangle designs is attained the set is said to be complete. Complete sets are obtained for all v for which v is a prime power. The construction method makes use of the existence of a complete set of pairwise orthogonal Latin square designs and of an orthogonal array with vⁿ columns, (vⁿ−1)/(v−1) rows, v symbols, and of strength two.