Selection and screening procedures to determine optimal product designs

To compare several promising product designs, manufacturers must measure their performance under multiple environmental conditions. In many applications, a product design is considered to be seriously flawed if its performance is poor for any level of the environmental factor. For example, if a particular automobile battery design does not function well under temperature extremes, then a manufacturer may not want to put this design into production. Thus, this paper considers the measure of a product's quality to be its worst performance over the levels of the environmental factor. We develop statistical procedures to identify (a near) optimal product design among a given set of product designs, i.e., the manufacturing design that maximizes the worst product performance over the levels of the environmental variable. We accomplish this by intuitive procedures based on the split-plot experimental design (and the randomized complete block design as a special case); split-plot designs have the essential structure of a product array and the practical convenience of local randomization. Two classes of statistical procedures are provided. In the first, the δ-best formulation of selection problems, we determine the number of replications of the basic split-plot design that are needed to guarantee, with a given confidence level, the selection of a product design whose minimum performance is within a specified amount, δ, of the performance of the optimal product design. In particular, if the difference between the quality of the best and second best manufacturing designs is δ or more, then the procedure guarantees that the best design will be selected with specified probability. For applications where a split-plot experiment that involves several product designs has been completed without the planning required of the δ-best formulation, we provide procedures to construct a ‘confidence subset’ of the manufacturing designs; the selected subset contains the optimal product design with a prespecified confidence level. The latter is called the subset selection formulation of selection problems. Examples are provided to illustrate the procedures.