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In the quest for continuous quality improvement of both products and processes, experimental design (ED) based on Shainin’s variables search method is still playing a major role in the manufacturing community. This article presents a simple methodology in a step‐by‐step manner for Shainin’s variables search method, in terms of uncovering the key process variables or factors which influence a response or quality characteristic of interest. In order to illustrate the potential of this powerful methodology as a problem solving tool, a simple catapult experiment was carried out. The authors believe that this simple experiment can be used in the classroom to train engineers and scientists on variables search method in order to identify the most critical variables which influence the process or product performance.

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