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Quality Improvement

through Planned

Experimentation

Third Edition

Ronald

D .

M oen

Thomas W . Nolan

Lloyd

P.

Provost

Me

Graw

Hill

ew

York Chicago San Francisco

Lisbon L ondon M adr id Mexico City

Milan New Delhi San Juan

Seoul Singapore Sydney Toronto

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ONTENTS

Foreword xiii

Preface xv

Acknowledgments xix

CHAPTER Improvement of Quality 1

1.1 Intro du ction 1

1.2 Building Knowledge and the Scientific

Method 2

1.3 Defining Quality 4

1.4 M odel for Im provem ent 9

1.5 Sequential Experim entation Using

the PDSA Cycle 19

1.6 Su m m ar y.; 21

References 22

Exercises 23

CHAPTER 2 Principles for Design and Analysis of

Planned Experiments 25

2.1 Intro du ction and Definitions 25

2.2 Types of Planned Experiments 29

2.3 Principles for Designing Analytic

Studies 34

2.4 Tools for Experim entation 40

2.5 Form for D ocu m entation ofaPlanned

Experiment y 51

2.6 Analysis of Data from Analytic Studies 54

2.7 Sum mary 58

References 58

Exercises 59

VII

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VIII ontents

CHAPTER 3 Experiments w ith One Factor 63

3.1 General App roach to One-Factor

Experiments 64

3.2 Using Run Charts for a On e-Fac tor

Design 68

3.3 Using Shewhart Charts for One-Factor

Experiments 76

3.4 Paired-C om parison Experiments 79

3.5 Random ized Block Designs 85

3.6 Incom plete Block Designs 95

3.7 Sum mary 103

References 104

Exercises 104

CHAPTER 4 Experiments with More Than One Factor 109

4.1 Introdu ction to Factorial Designs I l l

4.2 Design of Factorial Experim ents 136

4.3 Advanced Topics in the Analysis of

Factorial Experim ents 142

4.4 Sum mary 156

References 156

Exercises 156

CHAPTER 5 Reducing the Size of Experiments 161

5.1 Intro du ction to Fractional Factorial

Designs 163

5.2 Fractional Factorial Designs M oderate

Current Knowledge 170

5.3 Fractiona l Factorial DesignsLow

Current Knowledge 183

5.4 Using Blocking to Design a Sequence of

Exp eriments ? 192

5.5 Sum mary 202

Appendix: Development of Other Blocking

Arrangements 204

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onten ts | ix

References 206

Exercises 207

CHAPTER 6 Evaluating Sources of Variation

211

6.1 Applications of Nested Designs 213

6.2 Plann ing and Analyzing an Experiment

with Nested Factors 221

6.3 M ore Complex Nested Designs 227

6.4 Sum mary 238

Appendix 6 A: Calculation of V ariance

Components 238

Appendix

6B:

Calculating and Com bining

Statistics X, S, or R) 244

References 245

Exercises 245

CHAPTER 7 Sequential Experimentation A

Case

Study

251

7.1 Improv ing a M illing Process Getting

Started 251

7.2 The First Improve m ent Cycle: C urren t

Performance of the Mills 255

7.3 The Second PDSA

Cycle:

Sources

ofVariation.. 261

7.4 The Third PDSA Cycle: Evaluating Mill

Cu tter Ven dors 263

7.5 The Fo urth PDSA Cycle: Screening Process

Variables 265

7.6 Th e Fifth PDSA Cycle: Evaluate Effect of

Imp rovem ents on the Mill Process 269

7.7 The Sixth PDSA Cycle: Evaluating

Im po rtant Factors 270

7.8 The Seventh PDSA Cycle: D eterm ining j

O ptim um Levels 275

7.9 The Eighth PDSA Cycle: Confirmation

of Improvem ents 277

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ontents

7.10 Final Actions of the Mill Im prov em ent

Team 277

Exercises 280

CHAPTER 8 Usin gaTime Series Response Variable 281

8.1 Incorp orating Experim ental Pa tterns

in a Tim e Series 281

8.2 Shew hart Ch arts 286

8.3 Designs for Sequential Experim enta tion

Using Time Series Response Variables 295

8.4 Sum mary 303

References 303

Exercises 304

CHAPTER 9 Experim ents with Factors at More Than

Two Levels

309

9.1 Factorial Designs with M ore Th an Two

Levels , 309

9.2 Aug menting 2

k

Factorial Designs with

Center Po ints 316

9.3 Three-Level Designs for Qu antitativ e

Factors 321

9.4 Experiments for Form ulations or

Mixtures 326

9.5 Experimental Designs for Com plex

Systems 337

9.6 Sum m ary 341

References 342

Exercises 342

CHAPTER 1 Applications in Health Care 345

10.1 Intro du ctio n J346

10.2 Ap plications 350

10.3 Sum mary 365

References

366

Exercises 367

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ontents

X I

CHAPTER 11 New Product Design

369

11.1 Introduction 369

11.2 Phase 0: Generate Ideas 372

11.3 Phase 1: Develop Concepts and

Define Product 377

11.4 Phase2:Test 397

11.5 Phase

3:

Produce Produ ct 413

11.6 Sum mary 414

References 415

Exercises 416

APPENDIX A Evaluating Measurem ent Systems

417

Glossary 457

Index 465