• adaptive sequential experiment;
  • design of experiments;
  • central composite design (CCD);
  • optimal designs;
  • response surface optimization

Most preset response surface methodology (RSM) designs offer ease of implementation and good performance over a wide range of process and design optimization applications. These designs often lack the ability to adapt the design on the basis of the characteristics of application and experimental space so as to reduce the number of experiments necessary. Hence, they are not cost-effective for applications where the cost of experimentation is high or when the experimentation resources are limited. In this paper, we present an adaptive sequential response surface methodology (ASRSM) for industrial experiments with high experimentation cost, limited experimental resources, and high design optimization performance requirement. The proposed approach is a sequential adaptive experimentation approach that combines concepts from nonlinear optimization, design of experiments, and response surface optimization. The ASRSM uses the information gained from the previous experiments to design the subsequent experiment by simultaneously reducing the region of interest and identifying factor combinations for new experiments. Its major advantage is the experimentation efficiency such that for a given response target, it identifies the input factor combination (or containing region) in less number of experiments than the classical single-shot RSM designs. Through extensive simulated experiments and real-world case studies, we show that the proposed ASRSM method outperforms the popular central composite design method and compares favorably with optimal designs. Copyright © 2012 John Wiley & Sons, Ltd.