The factorial design of experiments using process simulators has been introduced into the undergraduate chemical reaction-engineering course in each class during the previous three semesters (2003, 2005, and 2006). Each semester, different mode of instructions were. In 2003, students were asked to read themselves and perform factorial analysis. In 2005, student group was split into two groups and each group was instructed on factorial design at two differnt times. In 2006, entire class was instructed on factorial design. Each time, students were given projects in which there are numerous processing possibilities for operation and equipment sizes and asked to adapt a factorial design of experiments designed to minimize the number of simulations while identifying an optimum condition for system operation. Surveys were given at different times. The outcomes of these methodologies will be presented with problem examples and the student outcomes from the experience.