Statistical Process Control and Experimental Design

Hello,

I’m currently finishing up an undergrad in Statistics, starting a Masters in Statistics in the Fall. I’ve learned a bit about the subjects, Statistical Process Control and Experimental Design on my own through bo I’m about to complete my undergraduate degree in Statistics and will begin a Master’s in Statistics this Fall. Outside of my formal coursework, I’ve explored topics like Statistical Process Control (SPC) and Experimental Design through self-study, using books such as Statistics for Experimenters by Box.

I’m curious about how these fields are perceived in industry today. Some have told me that these areas are “dead”, does this mean universities no longer emphasize them, or that they’re no longer considered valuable for statisticians in industry? I’d love to hear perspectives from those working in the field.

2 Likes

In the medical research field, many people only care about whether there is a statistically significant analysis result, not whether the analysis process is reasonable - this is the value of a good statistician. Unfortunately, many clinicians/researchers do not realize this. I guess this is one of the reasons why some people feel that this field is dying. But statisticians are definitely valuable.

2 Likes

I got my start in statistics with a brief consulting project right out of college, helping a National Opinion Research Center (NORC) team implement TQM for a computer-assisted data entry process. As I recall, one point that Deming might have emphasized about his approach to statistical process control was that it could (and should) be quite simple technically. Maybe that’s not the sort of application that academic statisticians would warm up to?

But I wonder what you would hear from faculty involved in Operations Research. OR has such interesting problems and methods, with wide applicability. For example, stochastic control is deeply fascinating, and has numerous applications. I’ve argued that one reason biostatisticians have been bolluxing up dose-finding for going on 35 years now is that they can’t be bothered to learn even the basics in this field, such as the Kalman filter. (@Stephen Senn once demurred at this claim on Twitter, but wisely hedged his bet by subsequently citing my 2017 DTAT paper, which applied the Kalman filter in this context, in Statistical Issues in Drug Development 3ed.)

4 Likes

The flavor of research done by OR researchers in Design of Experiments is foreign to what is expected in medical statistics. A synonym of operations research might be applied decision analysis. The following paper by Nathan Kallus from Cornell is a good example:

Kallus, N. (2018). Optimal a priori balance in the design of controlled experiments. Journal of the Royal Statistical Society Series B: Statistical Methodology, 80(1), 85-112. link

We develop a unified theory of designs for controlled experiments that balance baseline covariates a priori (before treatment and before randomization) using the framework of minimax variance and a new method called kernel allocation. We show that any notion of a priori balance must go hand in hand with a notion of structure, since with no structure on the dependence of outcomes on baseline covariates complete randomization (no special covariate balance) is always minimax optimal. Restricting the structure of dependence, either parametrically or non-parametrically, gives rise to certain covariate imbalance metrics and optimal designs.

The interesting part of Kallus’s paper is the discussion of balanced designs from a mathematical point of view. The kernel allocation method as described has limitations in human subject experiments because test subjects need to all be available for assignment. In medical trials, subjects arrive sequentially, creating practical challenges.

Yet, compare that with the work on matched designs that date back to the early 1970’s with Donald Taves and Simon and Pocock. Taves has a pre-print from 2024 (Improving Clinical Trials) that compares recent matching/minimization algorithms (termed Flexible Minimization) with randomization on sample size vs selection bias metrics. Donald Taves has fortunately placed all of his academic work on minimization on Researchgate for study.

I wonder if we would still see such scientific atrocities as “non-comparative randomized trials” if knowledge of these methods was more acceptable to peer review. The late Douglas Altman discussed them in a BMJ article, and they were discussed in an old version of the CONSORT guidelines.

What I find interesting that does not seem to have been asked in the stats or OR literature: why can’t matched/minimized trials be designed so that there is actual error detection and channel redundancy (ie. 3 independent trials of 1/3 the N of an RCT), and then combined via confidence distribution meta-analysis methods, which would be especially valuable for examination of design assumptions, since individual patient data is available? We could substitute an assumption that groups are exchangeable (in expectation via randomization) with evidence that they are (partially) exchangeable in this particular case and discount the observed sample size accordingly. We might think of it as design with the physical act of cross-validation (instead of randomization).

Related Reference

Hirasawa, S (2006). An Application of Coding Theory into Experimental Design–Construction Methods for Unequal Orthogonal Arrays. (PDF)

Greenland, S. (2022). The causal foundations of applied probability and statistics. In Probabilistic and causal inference: The works of Judea Pearl (pp. 605-624) (PDF)

Greenland, S. (2023). Divergence versus decision P‐values: A distinction worth making in theory and keeping in practice: Or, how divergence P‐values measure evidence even when decision P‐values do not. Scandinavian Journal of Statistics, 50(1), 54-88. (link)

Xie, M., Singh, K., & Strawderman, W. E. (2011). Confidence distributions and a unifying framework for meta-analysis. Journal of the American Statistical Association, 106(493), 320-333. (PDF)

3 Likes

Coincidentally, the latest HDSR editorial on the counterbalancing attitudes of statistics and machine learning / computer science recalled the powerful approaches produced by Operations Research but also warned: “a discipline’s intellectual viability does not guarantee its professional vitality”.

3 Likes

Such a crass and cynical statement! I wonder if “professional vitality” ≡ “funding” in this Harvard POV.

1 Like

Hi,

I’ve done my PhD in design of experiments (DoE) and I have to admit that it is indeed a very niche field in statistics…
However, DoE is quite often used in industrial process, either for identifying meaningful process variables (screening designs), or to find a setting for a preselected set of variables that optimize some output (cost, yield, …). The main issue is that many people in the industry still like the “one-factor-at-time” approach (i.e. changing one factor in an experiment and see the change in the results) because it feels like you can see the actual change, even though this approach is sub-optimal (and ignores interactions). But, in general, once industries have started using DoE they stick to it !

I would recommend the book of Peter Goos (my former promotor): Optimal Design of Experiments, which is really accessible and give an insight on applied DoE cases.

4 Likes

Experimental design and statistical process control are very much alive in some sectors of industry, even if neglected by academic statistics & biostatistics departments. (You can sometimes find them better treated in academic industrial engineering departments.) One field that uses these is nonclinical biostatistics, a community poorly represented on this forum. Unfortunately many drug companies lack a nonclinical biostats team, and thus one-factor-at-a-time thinking is often viewed as the scientifically preferred approach, incorrectly so, as noted by @ABohynDOE .

See this lecture for an example of cutting edge non-academic work in experimental design. https://www.youtube.com/watch?v=SGNTUj0C8Ew

3 Likes

In line with @ChristopherTong ‘s observations, I learned experimental design while consulting for Corning Electronics in their capacitor manufacturing group. They used fractional factorial designs, central compositive designs, and other cool designs. We developed a response surface optimization of multiple response variables that capitalized on the excellent experimental designs that allowed stable estimation of interaction effects.

3 Likes

Great points. The ongoing push towards a New Industrialism may also make these topics popular again throughout academia and tech. Likely with at least some AI thrown in the mix :grin:

1 Like