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Fractional factorial design tutorial | PPT
Fractional Factorial Designs:
A Tutorial
Vijay Nair
Departments of Statistics and
Industrial & Operations Engineering
vnn@umich.edu
Design of Experiments (DOE)
in Manufacturing Industries
• Statistical methodology for systematically
investigating a system's input-output relationship to
achieve one of several goals:
– Identify important design variables (screening)
– Optimize product or process design
– Achieve robust performance
• Key technology in product and process development
Used extensively in manufacturing industries
Part of basic training programs such as Six-sigma
Design and Analysis of Experiments
A Historical Overview
• Factorial and fractional factorial designs (1920+)
 Agriculture
• Sequential designs (1940+)  Defense
• Response surface designs for process
optimization (1950+)  Chemical
• Robust parameter design for variation reduction
(1970+)
 Manufacturing and Quality Improvement
• Virtual (computer) experiments using
computational models (1990+)
 Automotive, Semiconductor, Aircraft, …
Overview
• Factorial Experiments
• Fractional Factorial Designs
– What?
– Why?
– How?
– Aliasing, Resolution, etc.
– Properties
– Software
• Application to behavioral intervention research
– FFDs for screening experiments
– Multiphase optimization strategy (MOST)
(Full) Factorial Designs
• All possible combinations
• General: I x J x K …
• Two-level designs: 2 x 2, 2 x 2 x 2, … 
(Full) Factorial Designs
• All possible combinations of the factor
settings
• Two-level designs: 2 x 2 x 2 …
• General: I x J x K … combinations
Will focus on
two-level designs
OK in screening phase
i.e., identifying
important factors
(Full) Factorial Designs
• All possible combinations of the factor
settings
• Two-level designs: 2 x 2 x 2 …
• General: I x J x K … combinations
Full Factorial Design
9.5
5.5
Algebra
-1 x -1 = +1
…
Full Factorial Design
Design Matrix
9 + 9 + 3 + 3
6
7 + 9 + 8 + 8
8
6 – 8 = -2
7
9
9
9
8
3
8
3
Fractional Factorial Designs
• Why?
• What?
• How?
• Properties
Treatment combinations
In engineering, this is the sample size -- no. of prototypes to be built.
In prevention research, this is the no. of treatment combos (vs number of subjects)
Why Fractional Factorials?
Full Factorials
No. of combinations

This is only for
two-levels
How?
Box et al. (1978) “There tends to be a redundancy in [full factorial designs]
– redundancy in terms of an excess number of
interactions that can be estimated …
Fractional factorial designs exploit this redundancy …”  philosophy
How to select a subset of 4 runs
from a -run design?
Many possible “fractional” designs
Here’s one choice
Need a principled approach!
Here’s another …
Need a principled approach for selecting FFD’s
Regular Fractional Factorial Designs
Wow!
Balanced design
All factors occur and low and high levels
same number of times; Same for interactions.
Columns are orthogonal. Projections …
 Good statistical properties
Need a principled approach for selecting FFD’s
What is the principled approach?
Notion of exploiting redundancy in interactions
 Set X3 column equal to
the X1X2 interaction column
Notion of “resolution”  coming soon to theaters near you …
Need a principled approach for selecting FFD’s
Regular Fractional Factorial Designs
Half fraction of a design = design
3 factors studied -- 1-half fraction
 8/2 = 4 runs
Resolution III (later)
X3 = X1X2  X1X3 = X2 and X2X3 = X1
(main effects aliased with two-factor interactions) – Resolution III design
Confounding or Aliasing
 NO FREE LUNCH!!!
X3=X1X2  ??
aliased
For half-fractions, always best to alias the new (additional) factor
with the highest-order interaction term
Want to study 5 factors (1,2,3,4,5) using a 2^4 = 16-run design
i.e., construct half-fraction of a 2^5 design
= 2^{5-1} design
X5 = X2*X3*X4; X6 = X1*X2*X3*X4;  X5*X6 = X1 (can we do better?)
What about bigger fractions?
Studying 6 factors with 16 runs?
¼ fraction of
X5 = X1*X2*X3; X6 = X2*X3*X4  X5*X6 = X1*X4 (yes, better)
Design Generators
and Resolution
X5 = X1*X2*X3; X6 = X2*X3*X4  X5*X6 = X1*X4
5 = 123; 6 = 234; 56 = 14 
Generators: I = 1235 = 2346 = 1456
Resolution: Length of the shortest “word”
in the generator set  resolution IV here
So …
Resolution
Resolution III: (1+2)
Main effect aliased with 2-order interactions
Resolution IV: (1+3 or 2+2)
Main effect aliased with 3-order interactions and
2-factor interactions aliased with other 2-factor …
Resolution V: (1+4 or 2+3)
Main effect aliased with 4-order interactions and
2-factor interactions aliased with 3-factor interactions
X5 = X2*X3*X4; X6 = X1*X2*X3*X4;  X5*X6 = X1
or I = 2345 = 12346 = 156  Resolution III design
¼ fraction of
X5 = X1*X2*X3; X6 = X2*X3*X4  X5*X6 = X1*X4
or I = 1235 = 2346 = 1456  Resolution IV design
Aliasing Relationships
I = 1235 = 2346 = 1456
Main-effects:
1=235=456=2346; 2=135=346=1456; 3=125=246=1456; 4=…
15-possible 2-factor interactions:
12=35
13=25
14=56
15=23=46
16=45
24=36
26=34
Balanced designs
Factors occur equal number of times at low and high levels; interactions …
sample size for main effect = ½ of total.
sample size for 2-factor interactions = ¼ of total.
Columns are orthogonal  …
Properties of FFDs
How to choose appropriate design?
Software  for a given set of generators, will give design,
resolution, and aliasing relationships
SAS, JMP, Minitab, …
Resolution III designs  easy to construct but main effects
are aliased with 2-factor interactions
Resolution V designs  also easy but not as economical
(for example, 6 factors  need 32 runs)
Resolution IV designs  most useful but some two-factor
interactions are aliased with others.
Selecting Resolution IV designs
Consider an example with 6 factors in 16 runs (or 1/4 fraction)
Suppose 12, 13, and 14 are important and factors 5 and 6 have no
interactions with any others
Set 12=35, 13=25, 14= 56 (for example) 
I = 1235 = 2346 = 1456  Resolution IV design
All possible 2-factor interactions:
12=35
13=25
14=56
15=23=46
16=45
24=36
26=34
PATTERN OE-DEPTH DOSE TESTIMO
NIALS
FRAMING EE-DEPTH SOURCE SOURCE-
DEPTH
+----+- LO 1 HI Gain HI Team HI
--+-++- HI 1 LO Gain LO Team HI
++----+ LO 5 HI Gain HI HMO LO
+---+++ LO 1 HI Gain LO Team LO
++-++-+ LO 5 HI Loss LO HMO LO
--+--++ HI 1 LO Gain HI Team LO
+--+++- LO 1 HI Loss LO Team HI
-++---- HI 5 LO Gain HI HMO HI
-++-+-+ HI 5 LO Gain LO HMO LO
-++++-- HI 5 LO Loss LO HMO HI
----+-- HI 1 HI Gain LO HMO HI
-+-+++- HI 5 HI Loss LO Team HI
Factors Source Source-Depth
OE-Depth X X
Dose X X
Testimonials X
Framing X
EE-Depth X
Effects Aliases
OE-Depth*Dose = Testimonials*Source
OEDepth*Testimonials = Dose*Source
OE-Depth*Source = Dose*Testimonials
Project 1: 2^(7-2) design
32 trx
combos
Role of FFDs in Prevention Research
• Traditional approach: randomized clinical trials of control
vs proposed program
• Need to go beyond answering if a program is effective 
inform theory and design of prevention programs 
“opening the black box” …
• A multiphase optimization strategy (MOST)  center
projects (see also Collins, Murphy, Nair, and Strecher)
• Phases:
– Screening (FFDs) – relies critically on subject-matter knowledge
– Refinement
– Confirmation

Fractional factorial design tutorial

  • 1.
    Fractional Factorial Designs: ATutorial Vijay Nair Departments of Statistics and Industrial & Operations Engineering vnn@umich.edu
  • 2.
    Design of Experiments(DOE) in Manufacturing Industries • Statistical methodology for systematically investigating a system's input-output relationship to achieve one of several goals: – Identify important design variables (screening) – Optimize product or process design – Achieve robust performance • Key technology in product and process development Used extensively in manufacturing industries Part of basic training programs such as Six-sigma
  • 3.
    Design and Analysisof Experiments A Historical Overview • Factorial and fractional factorial designs (1920+)  Agriculture • Sequential designs (1940+)  Defense • Response surface designs for process optimization (1950+)  Chemical • Robust parameter design for variation reduction (1970+)  Manufacturing and Quality Improvement • Virtual (computer) experiments using computational models (1990+)  Automotive, Semiconductor, Aircraft, …
  • 4.
    Overview • Factorial Experiments •Fractional Factorial Designs – What? – Why? – How? – Aliasing, Resolution, etc. – Properties – Software • Application to behavioral intervention research – FFDs for screening experiments – Multiphase optimization strategy (MOST)
  • 5.
    (Full) Factorial Designs •All possible combinations • General: I x J x K … • Two-level designs: 2 x 2, 2 x 2 x 2, … 
  • 6.
    (Full) Factorial Designs •All possible combinations of the factor settings • Two-level designs: 2 x 2 x 2 … • General: I x J x K … combinations
  • 7.
    Will focus on two-leveldesigns OK in screening phase i.e., identifying important factors
  • 8.
    (Full) Factorial Designs •All possible combinations of the factor settings • Two-level designs: 2 x 2 x 2 … • General: I x J x K … combinations
  • 9.
  • 13.
  • 15.
  • 17.
  • 18.
    9 + 9+ 3 + 3 6 7 + 9 + 8 + 8 8 6 – 8 = -2 7 9 9 9 8 3 8 3
  • 24.
    Fractional Factorial Designs •Why? • What? • How? • Properties
  • 25.
    Treatment combinations In engineering,this is the sample size -- no. of prototypes to be built. In prevention research, this is the no. of treatment combos (vs number of subjects) Why Fractional Factorials? Full Factorials No. of combinations  This is only for two-levels
  • 26.
    How? Box et al.(1978) “There tends to be a redundancy in [full factorial designs] – redundancy in terms of an excess number of interactions that can be estimated … Fractional factorial designs exploit this redundancy …”  philosophy
  • 27.
    How to selecta subset of 4 runs from a -run design? Many possible “fractional” designs
  • 28.
  • 29.
    Need a principledapproach! Here’s another …
  • 30.
    Need a principledapproach for selecting FFD’s Regular Fractional Factorial Designs Wow! Balanced design All factors occur and low and high levels same number of times; Same for interactions. Columns are orthogonal. Projections …  Good statistical properties
  • 31.
    Need a principledapproach for selecting FFD’s What is the principled approach? Notion of exploiting redundancy in interactions  Set X3 column equal to the X1X2 interaction column
  • 32.
    Notion of “resolution” coming soon to theaters near you …
  • 33.
    Need a principledapproach for selecting FFD’s Regular Fractional Factorial Designs Half fraction of a design = design 3 factors studied -- 1-half fraction  8/2 = 4 runs Resolution III (later)
  • 34.
    X3 = X1X2 X1X3 = X2 and X2X3 = X1 (main effects aliased with two-factor interactions) – Resolution III design Confounding or Aliasing  NO FREE LUNCH!!! X3=X1X2  ?? aliased
  • 35.
    For half-fractions, alwaysbest to alias the new (additional) factor with the highest-order interaction term Want to study 5 factors (1,2,3,4,5) using a 2^4 = 16-run design i.e., construct half-fraction of a 2^5 design = 2^{5-1} design
  • 37.
    X5 = X2*X3*X4;X6 = X1*X2*X3*X4;  X5*X6 = X1 (can we do better?) What about bigger fractions? Studying 6 factors with 16 runs? ¼ fraction of
  • 38.
    X5 = X1*X2*X3;X6 = X2*X3*X4  X5*X6 = X1*X4 (yes, better)
  • 39.
    Design Generators and Resolution X5= X1*X2*X3; X6 = X2*X3*X4  X5*X6 = X1*X4 5 = 123; 6 = 234; 56 = 14  Generators: I = 1235 = 2346 = 1456 Resolution: Length of the shortest “word” in the generator set  resolution IV here So …
  • 40.
    Resolution Resolution III: (1+2) Maineffect aliased with 2-order interactions Resolution IV: (1+3 or 2+2) Main effect aliased with 3-order interactions and 2-factor interactions aliased with other 2-factor … Resolution V: (1+4 or 2+3) Main effect aliased with 4-order interactions and 2-factor interactions aliased with 3-factor interactions
  • 41.
    X5 = X2*X3*X4;X6 = X1*X2*X3*X4;  X5*X6 = X1 or I = 2345 = 12346 = 156  Resolution III design ¼ fraction of
  • 42.
    X5 = X1*X2*X3;X6 = X2*X3*X4  X5*X6 = X1*X4 or I = 1235 = 2346 = 1456  Resolution IV design
  • 43.
    Aliasing Relationships I =1235 = 2346 = 1456 Main-effects: 1=235=456=2346; 2=135=346=1456; 3=125=246=1456; 4=… 15-possible 2-factor interactions: 12=35 13=25 14=56 15=23=46 16=45 24=36 26=34
  • 44.
    Balanced designs Factors occurequal number of times at low and high levels; interactions … sample size for main effect = ½ of total. sample size for 2-factor interactions = ¼ of total. Columns are orthogonal  … Properties of FFDs
  • 45.
    How to chooseappropriate design? Software  for a given set of generators, will give design, resolution, and aliasing relationships SAS, JMP, Minitab, … Resolution III designs  easy to construct but main effects are aliased with 2-factor interactions Resolution V designs  also easy but not as economical (for example, 6 factors  need 32 runs) Resolution IV designs  most useful but some two-factor interactions are aliased with others.
  • 46.
    Selecting Resolution IVdesigns Consider an example with 6 factors in 16 runs (or 1/4 fraction) Suppose 12, 13, and 14 are important and factors 5 and 6 have no interactions with any others Set 12=35, 13=25, 14= 56 (for example)  I = 1235 = 2346 = 1456  Resolution IV design All possible 2-factor interactions: 12=35 13=25 14=56 15=23=46 16=45 24=36 26=34
  • 47.
    PATTERN OE-DEPTH DOSETESTIMO NIALS FRAMING EE-DEPTH SOURCE SOURCE- DEPTH +----+- LO 1 HI Gain HI Team HI --+-++- HI 1 LO Gain LO Team HI ++----+ LO 5 HI Gain HI HMO LO +---+++ LO 1 HI Gain LO Team LO ++-++-+ LO 5 HI Loss LO HMO LO --+--++ HI 1 LO Gain HI Team LO +--+++- LO 1 HI Loss LO Team HI -++---- HI 5 LO Gain HI HMO HI -++-+-+ HI 5 LO Gain LO HMO LO -++++-- HI 5 LO Loss LO HMO HI ----+-- HI 1 HI Gain LO HMO HI -+-+++- HI 5 HI Loss LO Team HI Factors Source Source-Depth OE-Depth X X Dose X X Testimonials X Framing X EE-Depth X Effects Aliases OE-Depth*Dose = Testimonials*Source OEDepth*Testimonials = Dose*Source OE-Depth*Source = Dose*Testimonials Project 1: 2^(7-2) design 32 trx combos
  • 48.
    Role of FFDsin Prevention Research • Traditional approach: randomized clinical trials of control vs proposed program • Need to go beyond answering if a program is effective  inform theory and design of prevention programs  “opening the black box” … • A multiphase optimization strategy (MOST)  center projects (see also Collins, Murphy, Nair, and Strecher) • Phases: – Screening (FFDs) – relies critically on subject-matter knowledge – Refinement – Confirmation