A Robust Cargo Box Structure Development using DFSS Methodology

Cargo box is a key structure in a pickup truck used to hold cargo load. Therefore, a cargo box must be durable and robust under different ballast conditions when subjected to road load inputs. This paper discusses a DFSS approach to resolve a durability concern observed on box bed in its early development phase. Traditional methods and best practices resulted in multiple iterations without an obvious solution. Hence, Design For Six Sigma (DFSS) tools were proposed to find an robust and optimum solution. Key control factors/design parameters were identified, and L18 Orthogonal Array was chosen to optimize design using CAE tools. An optimum design selected was the one with minimum stress level and least stress variation. This design was confirmed to have significant improvement and robustness compared to the initial design. All other load cases are also checked and verified without concern for the selected design.