Design of Experiments (DOE)

Data-Driven Process Improvements with Design of Experiments (DOE)

At EnerTherm Engineering, our Design of Experiments (DOE) services empower businesses to systematically explore and optimize the factors influencing their processes. By testing and analyzing multiple variables, our DOE approach uncovers critical insights, enhancing process control, product consistency, and operational efficiency.

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Overview of Our Design of Experiments (DOE) Service
Design of Experiments (DOE)

Design of Experiments (DOE) is a systematic methodology used to identify the relationships between factors affecting a process and the output of that process. It involves planning, conducting, analysing, and interpreting controlled tests to evaluate how various factors control the value of a parameter or group of parameters. DOE is essential in fields such as engineering, manufacturing, and biology for optimising processes, improving product design, and enhancing quality control.

Key Principles of DOE:

  • 1. Randomisation

  • Randomly assigning experimental units to treatment groups to mitigate the effects of uncontrolled variables and biases.

  • 2. Replication

  • Repeating experiments to estimate variability in the data and ensure consistent and reliable results.

  • 3. Blocking

  • Grouping similar experimental units together to reduce variability and increase the accuracy of the experiment.

 

Types of Experimental Designs:

  • 1. Factorial Designs

  • Used to evaluate the effect of multiple factors and their interactions.

  • 2. Response Surface Methodologies

  • Help find optimal operating conditions for processes.

  • 3. Custom Designs

  • Tailored for specific kinds of investigations and levels of complexity.

DOE allows researchers and engineers to systematically and efficiently explore the effects of multiple factors, leading to more robust and reliable conclusions about the processes they are studying. This approach saves time and resources by identifying the most influential factors with fewer experiments compared to one-factor-at-a-time methods.

Our Process for Design of Experiments (DOE)
R&D - DOE Process

The DOE process can be broken down into several key steps, ensuring a structured approach to experimentation. This structured approach allows for systematic investigation and optimisation of the factors affecting a process or product.

  • 1. Planning

  • Define Objectives: Clearly outline the purpose and goals of the experiment.
  • Identify Factors and Levels: Select the independent variables (factors) that could influence the outcome, and determine their levels.
  • Ensure Statistical Control: Verify that the process is stable and that the measurement system is reliable.

  • 2. Screening

  • Select Significant Factors: Conduct preliminary experiments to identify which factors significantly affect the outcome. This step reduces the number of variables for further study.
  • Design Selection: Use designs like Fractional Factorial, Plackett-Burman, or Definitive Screening Designs to efficiently identify important factors.

  • 3. Modelling

  • Develop Models: Build a mathematical model to describe the relationship between significant factors and the response variable.
  • Experiment Design: Apply designs such as Full Factorial or Fractional Factorial to understand these relationships in depth.

  • 4. Optimisation

  • Optimise Conditions: Adjust the levels of significant factors to find the optimal conditions for the desired outcome.
  • Designs for Optimisation: Use Central Composite Design or Box-Behnken Design for detailed exploration of factor interactions and optimisation.

  • 5. Verification

  • Confirm Results: Run experiments under the optimised conditions to validate the model and ensure the outcomes are as expected.
  • Iterate if Necessary: If results are not satisfactory, refine the model and optimisation parameters and verify again.

  • 6. Execution

  • Run Experiments: Conduct the experiments as per the selected design. Ensure consistency and control over all factors and conditions.
  • Data Collection: Collect and record all relevant data meticulously during the experiments.

  • 7. Analysis

  • Data Analysis: Use statistical tools and graphical methods to analyse the collected data. Look for patterns, correlations, and interactions between factors.
  • Interpret Results: Draw conclusions from the analysis to understand the effects of different factors on the outcome.
  • Build Predictive Models: Utilize advanced techniques such as neural networks (SANN), artificial intelligence (AI), and machine learning algorithms to develop predictive models. These models can forecast outcomes based on various input parameters, enhancing the decision-making process.

  • 8. Utilisation

  • Apply Findings: Use the results to make informed decisions and improvements in the process or product.
  • Document and Present: Document the experiment process, findings, and insights. Share the results with relevant stakeholders and consider further experimentation if needed.

By following these steps, you can ensure that your experimentation is thorough and your results are reliable. Implementing DOE effectively can lead to significant improvements in your processes and products.

Benefits of Our Design of Experiments (DOE)
R&D - DOE Benefits

Design of Experiments (DOE) offers numerous advantages for optimising processes and enhancing product quality.

Here are some key benefits to highlight on your service page:

  • 1. Systematic Exploration of Variables

  • DOE allows for the systematic investigation of multiple factors simultaneously. This enables the identification of key factors and their optimal levels, leading to improved product and process performance. This approach is more efficient than traditional methods that vary one factor at a time (OFAT).

  • 2. Optimisation of Processes and Products

  • By using DOE, organisations can optimise various aspects of their processes and products. This includes enhancing quality, reducing costs, and increasing efficiency. The method helps in finding the best settings for multiple variables that influence the desired outcome.

  • 3. Reduction of Defects and Variations

  • DOE helps identify the root causes of defects and variations in processes. By conducting controlled experiments, it becomes possible to pinpoint specific factors that contribute to issues and develop strategies to mitigate them, thereby improving overall quality and consistency.

  • 4. Interaction Analysis

  • One of the significant benefits of DOE is its ability to analyse interactions between variables. Understanding how different factors interact can reveal complex relationships and synergies that would not be apparent through OFAT methods. This insight is crucial for optimising multifactorial systems.

  • 5. Efficient Data Collection

  • DOE is a structured approach that ensures efficient and effective data collection. This systematic methodology reduces the number of experiments needed, saving time and resources while still providing comprehensive insights into the factors affecting the outcome.

  • 7. Improved Process Validation

  • DOE plays a critical role in process validation and verification. It helps gather data on process performance and determine critical process parameters, ensuring that processes are robust and capable of consistent performance under varied conditions.

  • 8. Support for Continuous Improvement

  • DOE is integral to continuous improvement methodologies like Six Sigma. It helps identify critical process parameters and set optimal levels, which are essential for minimising defects and achieving process excellence.

By leveraging these benefits, your organisation can achieve significant improvements in product quality, process efficiency, and overall operational effectiveness. Design of Experiments provides a scientific approach to problem-solving and optimisation, making it an invaluable asset for any quality-focused organisation.

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