Module 5 · Lesson 12 of 17
Planning a practical garment-factory experiment
This lesson and the entire Lean Six Sigma Black Belt academy are free of charge — no fees, ever.
Learning objectives
- Explain the purpose of planning a practical garment-factory experiment in a garment-factory improvement project.
- Apply the described method to a representative shop-floor situation.
- Recognize the common mistakes and how to avoid them.
Concept
A practical DOE plan joins statistical design with safety, production, material, measurement, and operational controls.
Include purpose, hypotheses, factors/ranges, response, sample size, random order, blocks, replication, material lots, gauge readiness, hold/release rules, safety, stop criteria, data sheet, and approvals.
Deviations must be recorded and never silently replaced by convenient runs.
Variables, units, and assumptions
Temperature (°C), pressure (kPa), dwell (s); bond strength (N/cm).
Gauge repeatable, panels representative of lot, operators trained.
Free-spreadsheet workflow
Free spreadsheet: list all runs, assign random order with RAND(), block by lot, execute, record Y and deviations.
Interpretation and limitations
Compare effect estimates to replicate SD to judge significance and practical importance.
Findings valid only within tested ranges and lot conditions.
Garment-factory example
Test fusing temperature, pressure, and dwell time using panels blocked by fabric lot, with bond strength and appearance responses.
Method
- Confirm MSA.
- Complete risk review.
- Generate run sheet.
- Label specimens.
- Brief the team.
- Execute randomized runs.
- Log deviations.
- Preserve samples.
Common mistakes
- Letting operators choose run order.
- Altering settings outside approved limits without documentation.
Knowledge check
Pick one answer per question. Explanations appear after you submit.
1. Deviations from the run plan must be:
2. Blocking by fabric lot controls:
Author: NOSK.life · Last reviewed: 2026-07-21