Design of Experiments Examples and Applications

DOE in Six Sigma

DOE is used alongside with Six Sigma practitioners in conducting experiments to:

  • Increase product quality
  • Increase yield
  • Reduce costs

DOE real-life applications in Six Sigma

Save cost by reducing variation among processes and extending tool life

By analyzing and understanding the factors that drive performance such as identifying product sensitivities and the root cause of manufacturing inefficiencies, National Semiconductor is able to identify ways to reduce defects and increase yield. The bottom line is increased throughput, speed and operating efficiency of its machines, all while maintaining equal or better quality products.

Read National Semiconductor’s full story in applying DOE and Six Sigma.

Reduce R&D cycle time by 50% in inventions

At China’s National Institute of Clean-and-Low-Carbon Energy (NICE), research scientists used to run experiments in the traditional way, one factor at a time. Ever since they adopted DOE along with Design for Six Sigma (DFSS) methodology in their R&D, they have reduced cycle time by half and seen an overall increase in their R&D competency level. The team has managed to complete more than 20 DFSS patented projects per year and has since received multiple Six Sigma excellence awards.

Read NICE’s full story in using DOE for its DFSS R&D projects.

DOE in Pharmaceutical Industry

DOE is mostly used in the pharmaceutical industry during its drug formulation phase and production phase.

DOE real-life applications in Pharmaceutical

Suppress and reduce impurities in drugs production phase

With a strong emphasis on quality control, Ono Pharmaceutical wanted to design an optimal manufacturing operation range using DOE. Before getting started, it was important for them to understand the interaction among multiple manufacturing parameters. Using DOE, Ono was able to create a matrix based on the interactions and set a design space that enabled the production of pharmaceutical ingredients with assured quality. Models with interaction parameters are important to Ono in suppressing impurities occurrence because when raw materials are in the process of becoming new pharmaceutical ingredients, impurities generated during the reaction may remain.

Read Ono’s full story in suppressing impurities occurrence with DOE.

Develop new formulation to control drug dissolution rate in human body

Some drugs are best delivered via a time-release schedule, dissolving slowly as they move through the body, and a special type of formulation is required to enable this. To design this type of formulation, Almac’s researchers use DOE to try out multiple different formulation ingredients (excipients), and manufacturing parameters to attain the correct drug release profile. With DOE’s help in multifactor investigation at minimal experimental runs, Almac is able to control costs for its clients as less costly raw materials are consumed in each experimental run.

Read Almac’s full story in developing formulation to control drug dissolution rate with DOE.

DOE in Fast-Moving Consumer Goods (FMCG) industry

DOE is mostly used in the FMCG industry during its product development phase, applied in wide range of experiments from consumer and sensorial panel testing to stability and reliability to accelerated experiments that look at how well products maintain their shelf life.

DOE real-life applications in FMCG

Optimize resources spent on running consumer studies

One of the biggest players in the FMCG industry, Procter & Gamble is behind many brands we use daily – Gillette, Bounty and Pampers, for example. P&G chose to embrace quantitative approach in developing winning products. Instead of conducting big consumer studies that use up immense resources, P&G is now doing more with less by collecting data in a more strategic way with the help of DOE. Optimal DOE has enabled the team to focus on what’s important and optimize the resources they spend running studies. In addition, optimal DOE also gives the team two or three optimal solutions that vary greatly in cost, providing the team options to go for the cheaper ones without compromising on quality.

Read P&G’s full story in using DOE to optimize resources spent in consumer studies.