The document outlines a class exercise for designing a fuel for a model motorcycle using three liquids with the goal of controlling distance traveled. Teams will conduct a full factorial design experiment to optimize liquid mixtures within a specified time frame, using safe, drinkable beverages to avoid damaging the motorcycle. Analysis of results will focus on achieving a target distance as determined by the instructor, with the winning team being the one closest to that target.

1. Design For Six Sigma DOE – Full Factorial Designs Class Exercise: Formula Fuelers ®

2. Background Information: You are going to make the fuel that powers this motorcycle. By experimenting with 3 different liquids, you will control the distance the motorcycle will travel. Your objective is to hit a target given to you by your instructor at the end of the experiment.

3. Background Information: How much time do I have to perform the experiment? How many people to a team? 1-1/2 hours 15 min. setup 45 min. running experiment 30 min. analyze & present 2 – 4 ; depending on the size of the class

4. Setting-up the Experiment Only use beverage for this experiment – things you can drink. Chemicals could damage the fuel tank. Avoid hot liquids (e.g. hot coffee or hot cocoa) because it could damage the plastic fuel tank. Cool them down first (i.e., ice). Dilute the beverages with water. Using coffee or juice in its natural concentration will cause the motorcycle to travel more than 25 feet.

5. Setting-up the Experiment A = 1 part coffee + 1 part water B = 1 part juice + 2 parts water C = soda (e.g. Sprite ® ) Liquid

6. Setting-up the Experiment Things You Will Need: Formula Fueler Motorcycle with Fuel Tank Tape Measure (Length  25 feet) AA Batteries (Quantity = 3) Small Paper Cups (at least 4) Paper Towels 5 ml Syringe Small bucket or large cup (to pour out used fuel) Optional: Extra Fuel Tank Extra Syringes (one for each observation)

7. The Experiment: Full Factorial Design 3 Factors: 2 Levels: -1 = do not use or absent from fuel tank 1 = add to fuel tank Response Variable: Liquid A Liquid B Liquid C Distance to the nearest ¼ inch.

8. Setting-Up the Experiment in Minitab

9. Setting-up the Experiment in Minitab

10. Treatments: How Much of Each Liquid? A B C A ml B ml C ml Total ml -1 -1 -1 0 0 0 0 1 -1 -1 6 0 0 6 -1 1 -1 0 6 0 6 1 1 -1 3 3 0 6 -1 -1 1 0 0 6 6 1 -1 1 3 0 3 6 -1 1 1 0 3 3 6 1 1 1 2 2 2 6

11. Launching the Motorcycle Push this power button. There will be a 2 second delay.

12. Response Variable: Measuring Distance Note: Motorcycle may not follow a straight line! Top View of Motorcycle Measure distance from start position to center of front-wheel to the closest 0.25 inch Starting Position

13. Procedure For Running Experiment With syringe, extract needed amount of liquids from cups marked A , B , and C . Open fuel tank and fill with syringe. Close fuel tank. Snap fuel tank into rear cavity of the Motorcycle. Position Motorcycle on Starting Line. Push power button. Wait for the Motorcycle to come to a stop. Measure the distance it traveled. Pick-up Motorcycle. Remove fuel tank. Open fuel tank cap and pour out contents.

14. Team Roles: Who Does What? Task 2 People 3 People 4 People Pick up motorcycle and remove fuel tank Person 1 Person 3 Person 1 Open cap and pour out the contents in the fuel tank Person 1 Person 1 Person 1 Collect samples of each liquid as specified per observation Person 1 Person 1 Person 2 Pour mixture into fuel tank and close the cap Person 1 Person 1 Person 2 Insert fuel tank into motorcycle Person 2 Person 1 Person 2 Position motorcycle on the floor in starting position Person 2 Person 2 Person 3 Press the power button and wait 2 seconds Person 2 Person 2 Person 3 Watch the vehicle run. Make sure it doesn't hit anything. When the it stops, take a measurement of how far it traveled Person 2 Person 3 Person 1 Enter the results into Minitab Person 2 Person 3 Person 4

15. Example of Experiment Data Collected

16. Analyze Results

17. Analyze Results

18. Analyze Results

19. Factorial Fit: DistInches versus Factor A, Factor B, Factor C Estimated Effects and Coefficients for DistInches (coded units) Term Effect Coef SE Coef T P Constant 86.91 0.3652 237.98 0.000 Factor A 47.19 23.59 0.3652 64.61 0.000 Factor B 47.02 23.51 0.3652 64.38 0.000 Factor C -22.85 -11.43 0.3652 -31.29 0.000 Factor A*Factor B -20.35 -10.18 0.3652 -27.87 0.000 Factor A*Factor C -5.23 -2.61 0.3652 -7.16 0.000 Factor B*Factor C -3.81 -1.91 0.3652 -5.22 0.000 Factor A*Factor B*Factor C 60.06 30.03 0.3652 82.24 0.000 S = 1.78900 R-Sq = 99.91% R-Sq(adj) = 99.86% Analysis of Variance for DistInches (coded units) Source DF Seq SS Adj SS Adj MS F P Main Effects 3 29759.6 29759.6 9919.9 3099.45 0.000 2-Way Interactions 3 2737.0 2737.0 912.3 285.06 0.000 3-Way Interactions 1 21645.0 21645.0 21645.0 6762.97 0.000 Residual Error 16 51.2 51.2 3.2 Pure Error 16 51.2 51.2 3.2

20. Analyze Results

21. Analyze Results

22. Do Any of the Lines Intersect?

23. Which Factor Has the Steepest Slope?

24. Cube Plots: Determine Settings to Meet Goal

25. Hitting A Target Objective: The instructor will give each team a number, which represents a distance the team must meet. If the motorcycle goes past this mark, the team loses. The winning team is the one who can come closest to the mark. The instructor may take the average of several runs (e.g., the average distance after 3 attempts) The target distance for your team is _______ inches. What fuel mixture will you make? (hint: Cube Plot)