Methods to construct supersaturated split-plot designs (SSSPDs) are presented. The authors use an E(s²)-optimal supersaturated design (SSD) in the whole-plot and half fractions of Plackett-Burman designs (PBDs) in the split plot. It is shown that (1) the resulting split-plot design has orthogonal columns, (2) the split-plot columns are orthogonal to the whole-plot columns, and (3) the whole-plot columns are orthogonal to the whole-plot by split-plot interactions. As an example, a SSSPD is applied to an extrusion process to produce biodegradable packaging foams, and data are analyzed using stepwise selection procedures. It is concluded that SSSPD can be used productively as a screening design when the experiment has a split-plot structure and traditional designs are not feasible.
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