Randomized Block Design - Example of A Randomized Block Design

Example of A Randomized Block Design

Suppose engineers at a semiconductor manufacturing facility want to test whether different wafer implant material dosages have a significant effect on resistivity measurements after a diffusion process taking place in a furnace. They have four different dosages they want to try and enough experimental wafers from the same lot to run three wafers at each of the dosages.

The nuisance factor they are concerned with is "furnace run" since it is known that each furnace run differs from the last and impacts many process parameters.

An ideal way to run this experiment would be to run all the 4x3=12 wafers in the same furnace run. That would eliminate the nuisance furnace factor completely. However, regular production wafers have furnace priority, and only a few experimental wafers are allowed into any furnace run at the same time.

A non-blocked way to run this experiment would be to run each of the twelve experimental wafers, in random order, one per furnace run. That would increase the experimental error of each resistivity measurement by the run-to-run furnace variability and make it more difficult to study the effects of the different dosages. The blocked way to run this experiment, assuming you can convince manufacturing to let you put four experimental wafers in a furnace run, would be to put four wafers with different dosages in each of three furnace runs. The only randomization would be choosing which of the three wafers with dosage 1 would go into furnace run 1, and similarly for the wafers with dosages 2, 3 and 4.