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DOE Is Primarily a Research Tool, Not a Production Tool

It’s overhyped and virtually of no benefit in production. The essential production tool is the control chart.

Anthony D. Burns
Mon, 10/28/2019 - 12:03
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Body

You’ve set aside Sunday afternoon to bake some cookies, but you discover you have run out of eggs. Your partner in marital bliss has gone out and taken the car. You call a couple of mates, and they tell you to try bananas, vegetable oil, or applesauce as egg substitutes. You decide to have some fun and mix it up on a few batches to see what’s best. Woohoo, you’re on the road to design of experiments (DOE).

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Transpose the above to a business situation, and you have a food technologist in a research laboratory. He has plenty of eggs, but he wants to cut the cost of using them. He doesn’t have any mates to call, but he has thousands of options such as mangoes, guava, and mashed potatoes instead of the banana; olive oil, peanut oil, sesame oil, and many others. He needs some way of measuring things. DOE gives a structured way to do experiments with a great number of known variables, by adjusting the many known factors in groups, with the minimum number of trials. It gives some clever sums to tell him which is best, with what interactions.

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Comments

Submitted by Sergey Grigoryev on Sat, 11/16/2019 - 19:23

Useful material for those who complicate simple things

Thanks, Dr. Tony Burns.

Useful material for those who complicate simple things with unnecessary complexity. I think this is happening to emphasize a certain elitism of certified specialists.

Yours faithfully,

Sergey Grigoryev

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Submitted by Mustafa Shraim (not verified) on Mon, 11/25/2019 - 17:26

Dear Tony, As you mentioned,

Dear Tony,

As you mentioned, traditional design of experiments (as well as Taguchi experiments) are offline methods. That is, you can't run them while in production. However, you can conduct DOE's in a manufacturing environment as long as you take the process out of production. This means that you do not use or ship to the customer any product resulting from the experimental combinations. I was involved in many experiments to identify the factors with the most impact on performance so they can be controlled appropriately - nothing wrong with that!

Best,

Mustafa

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Submitted by Manny Fernandez (not verified) on Sun, 12/15/2019 - 07:31

DOE Is Primarily a Research Tool....

Great article.  I whole heartedly support your take on how to best improve production.  There are no silver bullets or substitutes for understanding your process.  Observational investigation is key to understanding and moving forward.  Keep up the good work!

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Submitted by Stevenwachs on Wed, 04/15/2020 - 07:38

rubbish

I guess our clients are lying when they tell us the experiments we designed and analyzed for PRODUCTION PROCESSES, finally allowed them to understand how process variables (and design/formulation variables) affected key output characteristics and helped them to optimize designs AND process. 

DOE is a statistical method and has many uses in R&D, Design, and Production. 

Cannot disagree with the author any more stongly.

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