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The Expanding Role of Design of Experiments in Modern Manufacturing

Operational excellence as a strategic growth imperative

Vadym/Adobe

Jeffrey T. Slovin
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Minitab

Mon, 04/13/2026 - 12:03
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Manufacturers can’t control tariffs, supply chain volatility, labor shortages, or geopolitical instability. But they can manage operational efficiency.

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Operational excellence is one of the few factors that organizations can fully control. In challenging economic times, quality is an increasingly important competitive advantage.

Executive leadership should prioritize investment in quality and process improvement as strategic growth drivers, not merely as compliance requirements or cost centers. The growing adoption of design of experiments demonstrates this shift. Design of experiments (DOE) is a scientific method that helps you see how different inputs, or factors, influence an outcome by planning and running multiple controlled tests. Rather than changing just one thing at a time, DOE changes several factors together, efficiently. This approach shows which inputs are most important, how they interact, and how to achieve the best results. The main aim is to collect reliable data to build predictive models and improve products or processes more quickly and with fewer tests.

 …

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Comments

Submitted by dangermoney on Wed, 04/15/2026 - 11:28

You're dancing around at the surface

Too much talky talky sales pitch words, and not enough emphasis on how machine learning has completely changed the game with DOE. You'll sell a million Minitabs if you can make people understand how much better machine learning is. 

Traditional DOE requires the parameter space to be probed very rigidly. It's a big pain in the butt. For looking at a formulary space, you have to make the formulas that Minitab (or JMP or whatever) tells you to, and you have to make them right. You have to do all of your work up front, and then you get some answers that hopefully are useful because you performed the correct experiments so faithfully, and you chose the right region of the parameter space to explore. I'd just as soon stay in bed. It's often a lot faster to do one-dimensional ladder studies to probe the parameter space quickly, and then use intuition and experience to "Trial and Error" your way towards some optimum; navigate the interactions and complexities as they come, instead of performing a million experiments to precisely describe them. 

For formulation work, machine learning changes everything. You can take the inputs and outputs for whatever samples you happened to make, and if those samples cover a decent span of the formulary space, you can get a model that maps the correlations between inputs and outputs very well. And if you have doubts about the model, you can do more experiments to better cover the parameter space. Some softwares will even recommend which further experiments to perform to most efficiently fill in the parameter space. 

DOE is so inflexible and so involved; there are almost always faster, albeit less scientifically rigourous, paths to the same good insights and decisions. Machine learning makes the process flexible enough to actually make it worth doing at all. You should lead with that, and the people will be eating up Minitabs left and right. 

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Submitted by Josh Zable (not verified) on Fri, 04/17/2026 - 12:59

In reply to You're dancing around at the surface by dangermoney

DOE + Machine Learning is Music To Our Ears, As is Effex

Dangermoney: I don't think DOE and machine learning are exclusive.  There are definitely ways machine learning can be used to help facilitate DOE - to leverage data you already have to build models incrementally. (And yes! Minitab has plenty of machine learning if that strikes your fancy.)
Furthermore, we've recently acquired Effex to bridge this gap: instead of running a DOE exactly as prescribed, Effex can help use historical data or incomplete experiments to help you build an experiment.  We'd love to hear more ideas from you.  Feel free to email me directly at jzable@minitab.com.

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Submitted by analyticsadvocate (not verified) on Thu, 04/16/2026 - 01:35

Iterative experimentation

Executive leadership support is critical and will definitely change the game for any organization interested in a more systematic and informative approach to experimentation but I'm not sure that Minitab can position itself here for a so-called AI driven iterative experimental approach, at least not yet.  There is a lot that can be learned from a traditional DOE approach, and in a sequential experimental workflow it can even mimic an iterative (response driven) approach, but the knowledge gap for proper application and use certainly can be daunting for many organizations.

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