Hi @I-love-jmp,
Welcome in the Community !
The error message you have seen may be encountered when you break the principle of heredity, for example introducing a quadratic effect or 2-factors interactions but without introducing the related main effects. DoE are based on three principles : effect sparsity, effect heredity and effect hierarchy, more infos and details on this answer : DoE Principles - JMP Community
Usually, making sure all main effects are present should help avoiding this message.
To be sure this message is linked to this problem, it would be better to have more context, perhaps a datatable that reproduces this problem (with anonymized data) ?
The "if possible" setting is used for design creation, and may impact the analysis. It basically tells JMP (and the coordinate exchange algorithm behind) a priority/ranking about the terms you want to investigate, the relative precision in estimates it has to calculate, and how it may allocate ressources (design points) in order to maximize the learning you want (with necessary effect and if possible effects).
Sometimes points may be allocated to estimate these effects, sometimes it is not possible, due to restrictions in the experimental space and/or experimental budget (number of runs) asked by the user. "If possible" effect terms don't increase the number of runs required, so you end up by default with the same number of runs as if you didn't enter these effects in the Model panel. That means in the analysis, you may or may not be able to estimate these effects depending on the allocation of points and aliases in the design, no matter your method of analysis.
More technical details here : Designs with If Possible Effects (jmp.com)
Stepwise modeling doesn't not assume by default effect heredity and effect hierarchy, it's an "agnostic" method that try to find the best model based on a criterion (AICc, BIC, p-values, ...). So you may end up with different models than with a Standard Least Squares approach (that does respect all DoE principles). I would clearly try to respect these principles in a DoE created dataset, and not remove a main effect (even if statistically non-significant) if higer order effects containing this factor are still present.
So Stepwise is working, even if you break effect heredity or hierarchy principle, as it is just evaluating a lot of possible models and using the terms that best improve the model.
As you're dealing with a dataset with a specific structure and data generation, I would not recommend using data mining/"agnostic" modeling methods like Stepwise, except if you want to compare your previous modeling with new insights from other approaches.
It's a strange situation, as generally BIC would penalize models with more terms than AICc due to the differences in their calculation : https://www.jmp.com/support/help/en/17.1/index.shtml#page/jmp/likelihood-aicc-and-bic.shtml
It's however not uncommon, as I was able to reproduce your situation very easily :
At the end, it's "only" an Information criterion that guides you in the modeling, what is interesting is to compare on which terms they agree, and on which terms they differ, evaluate the different models possible with other metrics (statistical significance of the model, R² and R² adjusted, RMSE of the model ...) depending on your goal, and make your decision on all these informations AND your domain expertise !
I hope this answer will help you,
Victor GUILLER
L'Oréal Data & Analytics
"It is not unusual for a well-designed experiment to analyze itself" (Box, Hunter and Hunter)