Objective: Although many things have been learned to this point and we have made progress, we are not quite there. Earlier in the project the team determined that thickness was the main problem relating to the high level of defects in the leveler plates. The analysis has been completed and we want to IMPROVE the process. You recommend using a Design of Experiments approach to realize a breakthrough improvement. The team brainstorms a long list of possible reasons why the thickness is not capable. From that list, the team has reduced it down to five factors they want to include in an experiment. They suspect interactions, so they conclude a full factorial will be required. They refer to the resolution matrix (found in your reading materials and in the Fractional Factorial Designs Lecture) and they find they can learn about the effects of those five factors in 32 experiments. The factors for the experiment are Depth, Temp, Pressure, R.P.M. and Time. Instructions for you: From the factorial experiment (below) calculate the interactions to determine confounding. 1. Fill in the interaction columns. (shaded in gray color) You will need to do this to answer #1 in the peach-colored area below. 2. Is the initial design below a resolution III, IV, V or Full Factorial (no resolution)? 3. The initial design below is a design that an consultant is recommending. Unfortunately, you learn some bad news. Your management has set your budget only allowing for 8 runs because the trials cost $600 a piece. Big Hint: One of the factors MAY be dropped from the study for economic reasons. What specific experimental design would you recommend? (You do not need to decide which factor to drop at this point.) 4. Using the resolution matrix found in your online textbook, what is the resolution for the design you're recommending? 5. Based on your new recommendation, what will the confounding pattern be in your results? Data: Factor Depth (-) 85 (+) 150 Temp 140 155 Pressure 850 2500 R.P.M. 4400 4800 Time 30 45 Factor Factor Factor Factor Factor I try to enter or and it does not work. Trial A B D E A'B A'C A'D A'E B'C B'D B'E C'D C'E D'E 1 + . + + + 2 + + + + + + - - + - 3 + + + + + + + 4 + + + + + 5 + + + + 6 + + + . + 7 + + + + - + + 8 + + + + + + + 9 + . + + + + + 10 . + + + 11 + + + + + 12 + + + + + + + 13 + + + + + 14 . 15 + + - + - 16 + + + 17 + 18 + 19 + 20 + + + - - + + + + + + + + + + + + + + - + + + 21 + + + 22 + + + + + 23 + + - . + 24 + + + + + + + 25 + + 26 + + + + 27 + + + 28 + + + + + + + + + + . + + + + + + + + + 29 + + + + + + 30 + + + + + + + 31 + + + + + 32 + + + + + + + + + + + + . +