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."
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.
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.
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.
This poster displays the abstract and results of an experiment done to optimize enzymatic assays. Experimenters tested buffer, detergent, salt, and cation combinations using a 384-well microtiter plate format. The presence of different detergents and their interactions with different buffers had a profound effect on the enzyme turnover.
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.