Via mixture design of experiments (DOE) Alberto-Culver developed a new line of scrubs that far exceeded the performance of what they thought was possible. The formulator said "We selected Design-Expert software from Stat-Ease because of its exceptional capabilities in the design and analysis of mixture experiments. The end result is that we can get products to market faster and at a lower cost than with conventional experiment designs."
A statistically based design of experiments (DOE) approach developed specifically for mixtures was used to formulate a blend of rayon fibers that produced maximal tampon absorbency.
Diasorin used DOE to evaluate the robustness of its process for manufacturing an alpha-1-antitrypsin (AAT) assay. The results provided a considerable degree of confidence that existing in-process quality control criteria sufficed for being assured of meeting finished product requirements. This case study provides an excellent example of how DOE can reduce the time required to perform a latitude study while delivering statistical analysis that increases the degree of confidence in the study.
Engineers at a major medical device manufacturer used RSM to successfully model a key process for their flagship product. The RSM model then became the foundation for development of robust specifications to ensure quality at six sigma levels.
A large printing company tasked a Lean Six Sigma project team with finding a way to reduce setup time and costs in a department consisting of 33 Kluge presses. The results of the DOE led to a reduction of 5% in printing costs by moving to a less expensive foil for that job, and other knowledge gained from the experiment led to a 40% reduction in setup time over the last two years.
Upsher-Smith Laboratories used response surface methods (RSM) to optimize a fluid bed coating process that was producing inconsistent results. Aided by Design-Expert software, scientists discovered a most desirable setup that gave consistent results within specifications with little variability. When transferred to production, the new setup provided excellent results.
A custom rubber molder used DOE to uncover a combination of material selection and manufacturing protocol that created unacceptable results. Armed with this process knowledge, they achieved breakthrough quality improvements.