Browse Topic: Six Sigma

Items (148)

A DFSS approach to optimize the Hood design parameters to improve durability performance

2022-01-092303/29/2022

ABSTRACT In the Vehicle front closure development process, it is very important to meet the durability functional attributes such as Fit and finish, slam event and ease of closing effort. Conventionally softer seal & bump-stop stiffness properties are required for better flushness, but a stiffer seal & bump-stop will help to arrest the hood over travel during the slam event. It is always a challenging and iterative process to arrive at an optimum combination of these design parameters to meet both the flushness and slam targets. This paper highlights the six sigma approach to identify the effect of various control factors like Seal & Bump stop stiffness, latch position, bump-stop design clearance to meet the durability functional attributes. This approach suggests optimum design which is less sensitive to noise factors such as build tolerances on the latch position and the bump-stop design clearance. The learnings from this paper will help to improve design at the early stages of the

VS, Krishnaraj, Golla, Rama Raju

Development of a CAE Modeling Technique for Heavy Duty Cargo Weight using a DFSS Methodology

2022-01-092503/29/2022

Cargo box is one of the indispensable structures of a pickup truck which makes it capable of transporting heavy cargo weights. This heavy cargo weight plays an important role in durability performance of the box structure when subjected to road load inputs. Finite element representation for huge cargo weights is always challenging, especially in a linear model under dynamic proving ground road load durability analysis using a superposition approach. Any gap in virtual modeling technique can lead to absurd cargo box modes and hence durability results. With the original computer aided engineering (CAE) approach, durability results could not correlate much with physical testing results. It was crucial to have the right and robust CAE modeling technique to represent the heavy weight to provide the right torsional mode of the cargo box and good durability results. As there were multiple variables owing to heavy cargo weight, Design for Six Sigma (DFSS) methodology was used to develop a

Pankaj, Ananta Vijaya, Nazir, Fazil, Zhang, Weidong, Guo, Mingchao

Study of Fuel in Oil Dilution Due to Aftertreatment Regeneration in Automotive Diesel Engine

2021-26-018409/22/2021

The Bharat Stage VI emission norms in India is driving the use of more complex after treatment systems for diesel engines. The after-treatment system typically includes DOC, DPF and SCR to reduce the engine out hydrocarbon, particulates & NOx respectively. For a durable functioning of the after-treatment system, cleaning of these components at regular intervals is required. One such method is to burn the diesel fuel inside DOC, to clean the DPF and SCR, a process called regeneration. Regeneration involves using extra diesel fuel injected into the exhaust stream, which gets oxidized in the DOC thereby regenerating the DPF or SCR. Present technology uses the existing injectors in the diesel engine for regeneration which is cost effective and simpler compared to the external hydrocarbon dosing system. In-cylinder hydrocarbon dosing is associated with the risk of fuel getting mixed with engine oil. This happens because the regeneration fuel is injected in the exhaust stroke where the

Vinay P, Ashwyn, Verma, Utkarsh, Goswami, Imon, Suresh, Swathy

Application of Metrology, Statistics, Root Cause Analysis, and Cost of Quality to Enable Quality Improvements and Implementation of Statistical Process Controls for Acceptance of Large Complex Assemblies

2021-01-002503/02/2021

For new aircraft production, initial production typically reveals difficulty in achieving some assembly level tolerances which in turn lead to non-conformances at integration. With initial design, tooling, build plans, automation, and contracts with suppliers and partners being complete, the need arises to resolve these integration issues quickly and with minimum impact to production and cost targets. While root cause corrective action (RCCA) is a very well know process, this paper will examine some of the unique requirements and innovative solutions when addressing variation on large assemblies manufactured at various suppliers. Specifically, this paper will first review a completed airplane project (Project A) to improve fuselage circumferential and seat track joins and continue to the discussion on another application (Project B) on another aircraft type but having similar challenges. The use of Project A and B is used here to ensure proprietary protection of internal and supplier

Hall, Thomas D.

Robust Design of Rear Suspension Trailing Arm for Durability using Design for Six Sigma (DFSS) Approach

2020-01-060204/14/2020

Vehicle suspension parts are subjected to variable road loads, manufacturing process variation and high installation loads in assembly process. These parts must be robust to usage condition to function properly in the field. Design for Six Sigma (DFSS) tools and Taguchi methodology was used to optimize initial rear suspension trailing arm design. Project identified key control factor/design parameters, which could be used to improve part robustness at the lowest cost. Optimized design performs well under higher road loads and meets stringent durability requirements. This paper evokes use of Design of Six Sigma (DFSS) methodology to design robust rear suspension trailing arm and study effect of selected design parameters on robustness, stress level/durability and part cost

Kathoke, Sunil, Michalowski, Krzysztof, Subramani, Vinothkumar, Korba, Ahmed, Archak, Vijay, Thakare, Sameer

Integration of Sensitivity Analysis and Design for Six Sigma (DFSS) Methodology into Transient Thermal Analysis

2020-01-138904/14/2020

In this paper we present an integrated approach which combines analysis of the effect of simultaneous variations in model input parameters on the component or system temperatures. The sensitivity analysis can be conducted by varying model input parameters using specific values that may be of interest to the user. The alternative approach is to use a structured set of parameters generated in the form of DFSS DOE matrix. The matrix represents a combination of simulation conditions which combine the control factors (CF) and noise factors. CF’s are the design parameters that the engineer can modify to achieve a robust design. Noise factors include parameters that are outside the control of the design engineer. In automotive thermal management, noise factors include changes in ambient temperature, exhaust gas temperatures or aging of exhaust system or heat shields for example. The integrated approach, presented in this paper, provides powerful tools that can significantly reduce the total

El-Sharkawy, Alaa, Sami, Amr, Arora, Dipan, Hekal, Abd El-Rahman

A Robust Cargo Box Structure Development using DFSS Methodology

2020-01-060104/14/2020

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.

Zhang, Weidong, Pankaj, Ananta, Mcguire, Scott, Guo, Mingchao, Wekerle, Martin, Michalowski, Krzysztof

Simple Robust Formulations for Engineers: An Alternate to Taguchi S/N

2020-01-060404/14/2020

Robust engineering is an integral part of the quality initiative, Design For Six Sigma (DFSS), in most companies to enable good designs and products for reliability and durability. Taguchi’s signal-to-noise ratio has been considered as a good performance index for robustness since many decades. An alternate approach that is direct and simple for measuring robustness is proposed. In this approach, robustness is measured in terms of an augmented output response and it is a composite index of variation and efficiency of a system. This formulation represents the engineering design intent of a product in a statistical sense, so engineers can understand, communicate, and resonate at ease. Illustrative formulations with case studies are discussed with respect to smaller-the-better, nominal-the-best, and dynamic responses. Confirmation runs of optimization show good agreement of the augmented response with the predictive models that are based on the additivity principle.

Chinta, Balakrishna

Parametric Modelling and Performance Analysis of HVAC Defroster Duct Using Robust Optimization Methodology

2020-01-125004/14/2020

Thermal comfort and safety of automotive passengers are the most important factors in the development of the automotive HVAC system. HVAC system is responsible for the demisting and defrosting of the vehicle’s windows and for creating/maintaining a pleasant environment inside the cabin by controlling airflow and temperature. Fog or ice which forms on the windshield is the main reason for invisibility and leads to major safety issue to the customers while driving. It has been shown that proper clear visibility for the windshield could be obtained with a better flow pattern and uniform flow distribution in the defrost mode of the HVAC system and defrost duct. Defroster performance has received significant attention from OEMs to meet the specific global performance standards of FMVSS103 and SAE J902. Therefore, defroster performance is seriously taken into consideration during the design of HVAC system and defroster duct. The HVAC unit provides hot air to the defroster duct which is

Khan, Mohsin, Khan, Mohsin, Valencia, Manuel, Garikipati, Nagababu, Garikipati, Nagababu, Marginean, Calin

A Study on the Development of Aerostructures Design for Assembly Guidelines and Their Effective Use to Proactively Identify Opportunities for Improvement in Mitigating Common Defects of the Aerostructures Assembly

2020-01-000903/10/2020

An Aircraft’s assembly process plays a vital part in its design, development and production phases and contributes to about half of the Total cost spent in its entire product lifecycle. Design For Assembly (DFA®) principles have been one of the proven effective methodologies in Automotive and Process industries. Use of DFA® principles have resulted in proactively simplifying and optimizing engineering designs with reduced product costs, and improved efficiencies in product design and performance. Standardization of Assembly guidelines is vital for “Design and Build” and “Build-To-Print” manufacturing supplier organizations. However, Standardizing design methodologies, through use of proven tools like Advanced Product Quality Planning, (APQP) are still in the initial stages in Aerospace part and process design processes. Thus, there is a tremendous opportunity for research on the application of the existing DFA® guidelines to optimize Engineering Aerospace Assembly processes aiming to

Rajamani, Mani Rathinam, Punna, Eshwaraiah

Leading Women in Engineering & Science: Kristin Edgerton, Lead Project Engineer

TBMG-3624503/01/2020

Metal Stamping: Converting Parts for Cost Savings

TBMG-3537210/01/2019

In today’s world of medical device manufacturing, cost pressures are very real. At the same time, cost savings can be just as real, especially when companies examine their manufacturing processes for greater efficiencies. One area that is gaining particular attention is metal stamping of previously machined, metal injection-molded, or laser-cut parts.

Structural Optimization of an Vehicle Seat Cushion Bolster Wrinkle Improvement

2019-01-142003/25/2019

In recent years, a problem about car seat covering wrinkles rate are gradually increasing. So think that first have to understand the principle of how the wrinkles are occurred at vehicle seat. In this research, the focus is seat cushion bolster wrinkles. For understand about cushion bolster wrinkles, so set the three goals as below. (1) Understand the wrinkle’s occurred mechanism. (2) Suggest a design solution for cushion bolster wrinkle by using DFSS1 analysis. (3) Optimize the solution to robust the wrinkle performance.

Wang, Tehchiang

“Taguchi Customer Loss Function” Based Functional Requirements

2018-01-058604/03/2018

Understanding customer expectations is critical to satisfying customers. Holding customer clinics is one approach to set winning targets for the engineering functional measures to drive customer satisfaction. In these clinics, customers are asked to operate and interact with vehicle systems or subsystems such as doors, lift gates, shifters, and seat adjusters, and then rate their experience. From this customer evaluation data, engineers can create customer loss or preference functions. These functions let engineers set appropriate targets by balancing risks and benefits. Statistical methods such as cumulative customer loss function are regularly applied for such analyses. In this paper, a new approach based on the Taguchi method is proposed and developed. It is referred to as Taguchi Customer Loss Function (TCLF). The “Taguchi Quality Loss Function (TQLF)” methodology has been used primarily to improve quality from a manufacturing standpoint, giving engineers a way to understand how

Chinta, Balakrishna, Mandadapu, Srinivasa

Application of Six Sigma Methodology to Improve Product Quality in Injection Molded Parts at Supplier End in Motorcycle Industry

2017-01-501109/29/2017

Process Parameters play a vital role in product quality of Injection Molded components. Variation in process parameters will lead to Injection Molded manufacturing defects like Sink Mark, Flow Mark, Silver Streak, Flash, Warping, Weld lines, Jetting, voids, Short Shot & Bubbles. This manuscript is innovative because suppliers (Tier 1 and Tier 2) do not use DoE for standardization of their process parameters in Injection Molding and High Pressure Die Casting. They do trial and error method to arrive at the process parameters which is error prone and time consuming. The variation of process parameters can be optimized using Six Sigma approach, a structured methodology which is Process focused & data driven approach. The purpose of this paper is to present through a case study how the concepts of Design of Experiments, which is a part of Six Sigma Methodology can be used for improving the Injection Molding Process at supplier end reducing defects & hence improving Quality at supplier

Shankaranarayana, Raviprakash

Efficient Procedure for Robust Optimal Design of Aerospace Laminated Structures

2017-01-205809/19/2017

Innovative aircraft design studies have noted that uncertainty effects could become significant and greatly emphasized during the conceptual design phases due to the scarcity of information about the new aero-structure being designed. The introduction of these effects in design methodologies are strongly recommended in order to perform a consistent evaluation of structural integrity. The benefit to run a Robust Optimization is the opportunity to take into account uncertainties inside the optimization process obtaining a set of robust solutions. A major drawback of performing Robust Multi-Objective Optimization is the computational time required. The proposed research focus on the reduction of the computational time using mathematic and computational techniques. In the paper, a generalized approach to operate a Robust Multi-Objective Optimization (RMOO) for Aerospace structure using MSC software Patran/Nastran to evaluate the Objectives Function, is proposed. A Multi-Objective

Noziglia, Francesco, Rigato, Paolo, Cestino, Enrico, Frulla, Giacomo, Arias-Montano, Alfredo

DMADV Approach for Engineering Optimization and Quality - Application and Adaptability in Indian Automobile Industry

2017-28-193007/10/2017

Indian Automobile Industry has started using Six Sigma for Vehicle Design and process improvement to compete with Global competition. This Paper describes how the Tools of Six Sigma shall be used as an Effective Tool for both redefining the Design and the Process Improvement. This Paper talks on the evolution of DMADV approach in Indian Automobile Industry compared to the related Trends in Other Manufacturing Sectors. The Author describes how the warranty failures in Commercial Segment Vehicle Category which was the selling talk for the Competition was addressed in Leading Indian Automobile OEM. As this Failure was adversely impacting customer satisfaction and no solution seemed forthcoming, top Management indicated to use a radically different approach to solve the problem within a years’ time. Among the different processes evaluated, DMADV six sigma approach brought in a creative approach to problem solving and improved systematic team work between the supplier, manufacturing

Jaswal, Anil Kumar, Chandrasekaran, Pradeep, Ramadoss, Surendran

Engineering Productivity Increase with Organization Architectures

2017-01-024803/28/2017

Motivation - Ambiguous product targets, a global market, innovation pressure, changing process requirements and limited resources describe the situation for engineering management in the most R&D organizations. Achieving complex objective with limited resources is a question of performance. Performance in engineering departments is highly correlated to the existing capability of the engineering staff. When the reduction of engineering effort in development projects becomes additional goal for the management, an increase of engineering productivity is required. International engineering sites are established globally to push the capacity limits and to increase the productivity by the accessing big employment markets of engineering talents. By solving the conflict of limited resources and complex engineering goals, a need organizational challenge occurs - global co-engineering. Co-engineering is the extension of simultaneous engineering by the distribution of tasks and responsibilities

Koark, Fabian Jorg Uwe, Korandla, Arvind

A DFSS Approach to Optimize the Second Row Floor Duct Using Parametric Modelling

2017-01-017603/28/2017

The main function of mobile air conditioning system in a vehicle is to provide the thermal comfort to the occupants sitting inside the vehicle at all environmental conditions. The function of ducts is to get the sufficient airflow from the HVAC system and distribute the airflow evenly throughout the cabin. In this paper, the focus is to optimize the rear passenger floor duct system to meet the target requirements through design for six sigma (DFSS) methodology. Computational fluid dynamics analysis (CFD) has been used extensively to optimize system performance and shorten the product development time. In this methodology, a parametric modeling of floor duct design using the factors such as crossectional area, duct length, insulation type, insulation thickness and thickness of duct were created using CATIA. L12 orthogonal design array matrix has been created and the 3D CFD analysis has been carried out individually to check the velocity and temperature. The impacts of each design

Vasanth, B., Putcha, Uday, Sathish Kumar, S., nukala, Ramakrishna, Govindarajalu, Murali

Robust 1D Modelling for Automotive HVAC Warmup Prediction Using DFSS Approach

2017-01-017903/28/2017

In an automotive air-conditioning (AC) system, the heater system plays a major role during winter condition to provide passenger comforts as well as to clear windshield defogging and defrost. In order to meet the customer satisfaction the heater system shall be tested physically in severe cold conditions to meet the objective performance in wind tunnel and also subjective performance in cold weather regions by conducting on road trials. This performance test is conducted in later stage of the program development, since the prototype or tooled up parts will not be available at initial program stage. The significance of conducting the virtual simulation is to predict the performance of the HVAC (Heating ventilating air-conditioning) system at early design stage. In this paper the development of 1D (One dimensional) model with floor duct systems and vehicle cabin model is studied to predict the performance. Analysis is carried out using commercial 1D simulation tool KULI®. All the

Sambandan, Saravanan, Valencia, Manuel, S, Sathish Kumar

Optimization for Brake Feeling in Vehicle without Brake Noise

2016-01-192809/18/2016

Recently, upon customer’s needs for noise-free brake, carmakers are increasingly widely installing damping kits in their braking systems. However, an installation of the damping kits may excessively increase softness in the brake system, by loosening stroke feeling of a brake pedal and increasing compressibility after durability. To find a solution to alleviate this problem, we first conducted experiments to measure compressibility of shims by varying parameters such as adhesive shims (e.g., bonding spec., steel and rubber thickness), piston’s shapes (e.g., different contact areas to the shims), and the numbers of durability. Next, we installed a brake feeling measurement system extended from a brake pedal to caliper. We then compared experimental parameters with brake feeling in a vehicle. Finally, we obtained an optimized level of brake feeling by utilizing the Design for Six Sigma (DFSS). Our results may provide practitioners with a better guideline by helping them design a brake

Jeong, ByeongUk, Kwak, Sang Do, Kim, Cheol Ki

Achieving Quality and Economy with Cold Forming

TBMG-2540409/01/2016

As medical devices become smaller, the need for precision microminiature components increases. This provides several challenges for the medical device manufacturer as they seek cost-effective parts meeting the exacting quality specifications that play a critical role in the overall performance of the medical device.

Adapting Design for Six Sigma (DFSS) Methodology for Diesel Lean NOx Trap (LNT) Catalyst Screening

2016-01-095304/05/2016

In order to meet LEV III, EURO 6C and Beijing 6 emission levels, Original Equipment Manufacturers (OEMs) can potentially implement unique aftertreatment systems solutions which meet the varying legislated requirements. The availability of various washcoat substrates and PGM loading and ratio options, make selection of an optimum catalyst system challenging, time consuming and costly. Design for Six Sigma (DFSS) methodologies have been used in industry since the 1990s. One of the earliest applications was at Motorola where the methodology was applied to the design and production of a paging device which Consumer Reports called “virtually defect-proof”.[1] Since then, the methodology has evolved to not only encapsulate complicated “Variation Optimization” but also “Design Optimization” where multiple factors are in play. In this study, attempts are made to adapt the DFSS concept and methodology to identify and optimize a catalyst for diesel applications. Lean NOx Trap (LNT) was selected

Ahari, Homayoun, Smith, Michael, Zammit, Michael, Walker, Brad

Optimization Solutions for Fan Shroud

2016-01-139304/05/2016

Fan shroud is one of the critical components in an engine cooling system. It helps in achieving optimum air flow across the heat exchangers. The major challenge is to design a fan shroud which meets noise, vibration and harshness (NVH) requirements without compromising on air flow targets [1]. An improperly designed fan shroud will cause detrimental effects such as undesirable noise and vibration, which will further damage the surrounding components. In current days, multiple simulations and test iterations are carried out in order to optimize its design. The objective of this paper is to provide a design framework to achieve optimized fan shroud that meets NVH requirements in quick turnaround time using Design for Six Sigma (DFSS) approach [2]. The purpose of the Engine cooling system is to maintain the coolant temperature across the vehicle. Fan shroud accommodates the fan which in turn provides necessary air distribution across the radiator in order to have effective engine cooling

Konikineni, Prabhakar, Sundaram, V., Sathish, Kumar, Thirukkotti, Sankarasubramanian

Directional Mahalanobis Distance and Parameter Sensitivities

2016-01-028904/05/2016

Mahalanobis Distance (MD) is gaining momentum in many fields where classification, statistical pattern recognition, and forecasting are primary focus. It is a multivariate method and considers correlation relationships among parameters for computing generalized distance measure to separate groups or populations. MD is a useful statistic in multivariate analysis to test that an observed random sample is from a multivariate normal distribution. This capability alone enables engineers to determine if an observed sample is an outlier (defect) that falls outside the constructed (good) multivariate normal distribution. In Mahalanobis-Taguchi System (MTS), MD is suitably scaled and used as a measure of severity in abnormality assessment. It is obvious that computed MD depends on values of parameters observed on a random sample. All parameters may not equally impact MD. MD could be highly sensitive with respect to some parameters and less sensitive to some other parameters. Knowledge of

Chinta, Balakrishna

SCALE Optical Hole Probe - The Next Step to Save Time and Cost in Auto Fastening with the Help of Optical Measurement Technology

2015-01-261809/15/2015

SCALE is a modular, non-contact, in-line measurement system. It measures the diameter of the countersink directly after the drilling, the amount and distribution of sealant in the open hole, and the head height of the fastener as well as pressed out sealant (cf. Figure 1). The system is fast and reliable and the out coming information is reliable and trustworthy. Until now the system could not measure the inner diameter of the hole. The reason for this is that it is not possible to detect the inner diameter with a camera that looks only at the top of the component. But as our customers make the request to us, we decided to develop an optical hole probe system which is fully integrated in the auto fastening process. We think that a mechanical system cannot fulfill the customer expectations in terms of reliability, low maintenance, precision and speed. Only a non-contact system can measure permanently safe and fast the inner diameter of holes. The development objective was to create a

Wolf, Bernd-Michael, Meiners, Christian

Automobile Powertrain Sound Quality Development Using a Design for Six Sigma (DFSS) Approach

2015-01-233606/15/2015

Automotive companies are studying to add extra value in their vehicles by enhancing powertrain sound quality. The objective is to create a brand sound that is unique and preferred by their customers since quietness is not always the most desired characteristic, especially for high-performance products. This paper describes the process of developing a brand powertrain sound for a high-performance vehicle using the DFSS methodology. Initially the customer's preferred sound was identified and analyzed. This was achieved by subjective evaluations through voice-of-customer clinics using vehicles of similar specifications. Objective data were acquired during several driving conditions. In order for the design process to be effective, it is very important to understand the relationship between subjective results and physical quantities of sound. Several sound quality metrics were calculated during the data analysis process. A House of Quality (HOQ) matrix was created to characterize this

Arvanitis, Anastasios, Orzechowski, Jeff, Tousignant, Todd, Govindswamy, Kiran

Optimization of MAC Side Window Demister Outlet by Parametric Modelling through DFSS Approach

2015-01-036304/14/2015

In recent years clearing the mist on side windows is one of the main criterions for all OEMs for providing comfort level to the person while driving. Visibility through the side windows will be poor when the mist is not cleared to the desired level. “Windows fog up excessively/don't clear quickly” is one of the JD Power question to assess the customer satisfaction related to HVAC performance. In a Mobile Air Conditioning System, HVAC demister duct and outlet plays an important role for removing the mist formation on vehicle side window. Normally demister duct and outlet design is evaluated by the target airflow and velocity achieved at driver and passenger side window. The methodology for optimizing the demister outlet located at side door trim has been discussed. Detailed studies are carried out for creating a parametric modeling and optimization of demister outlet design for meeting the target velocity. In this methodology, a parametric modeling of demister outlet design using the

Balashunmuganathan, Vasanth, Nukala, Ramakrishna, Sampath Kumar, Sathishkumar, Govindarajalu, Murali

Design For Six Sigma (DFSS) for Optimization of Stamping Simulation Parameters to Improve Springback Prediction

2015-01-058204/14/2015

Springback prediction for stamped components is a challenging task for Automotive Industry. Automotive Manufacturers are working to reduce the springback effect of sheet metal stampings caused due to elastic behavior of materials with the help of changes to manufacturing process and part geometry. Recent development in Finite Element Analysis (FEA) studies made it possible for the industry to rely on stamping simulation. There is always a gap between the springback predicted from stamping simulation and the actual stamped part. Currently FEA techniques are trying to close this gap. The objective of this study is to minimize this gap using DFSS method for predicting the springback and optimizing the simulation parameters with the help of LS-Dyna FEM tool. The behavior of material with different simulation parameters has been studied in this paper and the ones that best correlate with actual data are identified. The amount of springback is virtually measured for the stamped part with and

Bhuyan, Deepak Ranjan, Netapalli, Sreekanth, Dev, Sathya, Srinivasan, Soundarya

Creating a Two Sided Customer Loss Function

2015-01-135704/14/2015

In the area of Human Factors and Usability research a desired output of many studies is identification of what value a specific Design Parameter should be set at to minimize customer dissatisfaction. A Customer Loss Function is a simple way to graphically display the probability customers will be dissatisfied at different levels of a given design parameter, due to a given failure mode. Many design parameters however, have two distinct but related Failure Modes (customer disatisfiers), typically representing two ends of the parameter (i.e. too much/too little; too hot/too cold; too fast/too slow). Each of these Failure modes is represented by its own unique Customer Loss Function. This paper will introduce a technique to combine these two One-Sided Loss Functions into a comprehensive Two Sided Loss Function. The mathematics behind the creation of both one sided and two sided loss functions is based on Binary Logistic Regression [1,2,3] Analysis Techniques. The benefits of incorporating

Crowley, James A.

Development of a Lightweight Fixed Steering Column Applying DFSS Methodology

2014-36-010309/30/2014

Over recent years, demands for fuel-efficient vehicles have increased with the rise of the fuel price and public concerns on environment. Recently, application of lightweight materials is increasing in the automobile industry in order to improve mass reduction and consequently fuel efficiency. On this particular study, with a goal of developing a Lightweight Fixed Steering Column, it was identified an opportunity to replace fixed steering column metallic upper and lower brackets by polymeric material. In order to fulfill NVH, Crash, Durability and Performance requirements, a DFSS methodology has been applied. As a result, It was achieved ∼51% of mass reduction, ∼10% of performance improvement with ∼14% of cost increase.

Campos, Demerson Alves de

Five Strategies for Improving Aerospace Supply Chain Quality Management and Performance

2014-01-223109/16/2014

Aerospace suppliers face the daunting task of constantly improving time-to-market, reducing cost of quality and turning compliance into a competitive advantage. Managing to these constraints while staying profitable is a challenge faced by the entire aerospace supply chain face today. The intent of this presentation is to share five lessons learned on how aerospace suppliers can optimize for these three constraints while growing their businesses. The first is electronically enabling traceability both within a multi-tier supply chains and throughout suppliers. Automating traceability at the shop floor improves quality management and accelerates compliance. Specific methodologies and metrics used to accomplish this will be provided. Second, lessons learned from implementing Manufacturing Execution Systems (MES) showing how shop floor visibility has a direct effect on supplier performance is illustrated with case studies and metrics. Third, lessons learned in making compliance pay by

Columbus, Louis

Five Strategies for Improving Aerospace Supply Chain Quality Management and Performance

2014-01-2231-TEST-REC09/16/2014

Columbus, Louis

Optimization of TOC Plumbing Line Pressure Drop using 1D Modeling

2014-01-066004/01/2014

The performance of the Transmission Oil Cooler (TOC) is influenced significantly by the TOC plumbing lines which transmit the oil from transmission system to the oil cooler and back. Designing the optimum TOC plumbing line with lesser pressure drop is the need of the hour considering the complex nature of the vehicle packaging. Reducing the pressure drop increases the oil flow rate through the transmission which results in optimum performance. Improved transmission efficiency in turn shall improve the engine efficiency and performance. The improvements obtained from increased transmission and engine efficiency shall result in an overall increase in vehicle fuel economy. Optimization solutions are required in the early product development cycle where the components are not readily available and/or are prohibitively expensive to do testing. In such scenarios, one-dimensional (1D) simulations shall be employed to compute the pressure drop for faster and economical solutions. In this paper

Sundaram, V., Arthanari, Tharunnarayanan, S, Sathish Kumar

Implementation of Lean Transactional in Tenneco's Ride Performance Europe Division - Review after Three Years of Implementation

2014-01-076904/01/2014

After having successfully implemented Lean in Tenneco's Clean Air division, Tenneco Europe decided to expand Lean to its other divisions - Ride Performance including Aftermarket in 2011. These divisions were able to fully benefit from the best practices developed over the last 10 years. The implementation was articulated around two major axes: the execution of complex projects related to processes including several functions and sites. This approach allowed us to reach a critical mass in a reasonable time within the different functions and sites; the execution of smaller projects focused on one specific function,e.g.: Engineering or Sales. This approach is complementary to the first one since it enhances the spread of the lean spirit within the organization. This paper focuses on Tenneco's Ride Performance division and is split into two parts. Part 1 explains: the different steps required to implement the lean mindset; the challenges to implement it, i.e: the continuous improvement

Garcia, Patrick, Paparelli, Sandro

Prediction of Life Distribution and Design Robustness of Converter Joint Durability Using CAE Techniques

2014-01-091604/01/2014

A variety of parameters influence the durability of a converter to pipe joint of an automotive exhaust system. Some of the parameters are design variables and some factors are related to manufacturing. The design parameters include the thickness of the components, diameter of the pipe, sleeve length of the cone etc. While the variables like the weld penetration and the fit-up of the joint are related to manufacturing. Traditional durability simulations utilizing computer aided engineering (CAE) methods are conducted using nominal values of the design and manufacturing variables. In reality scatter and randomness in parameters are present due to the tolerance in components and limitations of the manufacturing process. In this paper a CAE based stochastic approach to determine the life distribution for a converter joint of an automotive exhaust system is presented. During the first step of the study, design of experiments (DOE) using finite element analysis (FEA) were conducted to

George, John, Joshi, Bharat, Shih, H.R., Chen, Yin

Critical Success Factors of Quality Culture Development in Automotive Industry

2013-01-133004/08/2013

Purpose - This research aimed to investigate the process of quality culture development in automotive industry in in order to identify the critical success factors. Design/methodology/approach - A review of relevant literature is used to identify potential critical success factors for quality culture development. The research had targeted quality directors, quality managers, and quality employees, and consultants working in automotive industry. Data were collected with an electronic survey which included 20 close ended questions, each measured by using five-point scale, Out of total 150 questionnaire distributed, 60 useable responses were received resulting in 40% response rate. A judgmental sampling technique had been selected. Both descriptive and inferential statistics had been used to analyze this data. Findings - Our findings indicated that the belief among the respondents that management engagement, communication, training, teamwork among others are critical success factors for

El Safty, Shady Baher

Integrated Virtual Approach for Optimization of Vehicle Sensitivity to Brake Torque Variation

2013-01-059604/08/2013

Brake judder is a brake induced vibration that a vehicle driver experiences in the steering wheel or floor panel at highway speeds during vehicle deceleration. The primary cause of this disturbance phenomenon is the brake torque variation (BTV). Virtual CAE tools from both kinematics and compliance standpoints have been applied in analyzing sensitivities of the vehicle systems to BTV. This paper presents a recently developed analytical approach that identifies parameters of steering and suspension systems for achieving optimal settings that desensitize the vehicle response to BTV. The analytical steps of this integrated approach started with creating a lumped mass noise-vibration-harshness (NVH) control model and a separate multi-body dynamics (MBD) suspension model. Then, both models were linked to run in a sequence through optimization software so the results from the MBD model were used as quasi-static inputs to the lumped mass NVH model. Considering control factor parameters

Zhang, Bo, Beyer, Charles, Pelkey, Jack, Whitehead, Glenn, Opeiko, Alexandre

A Statistical Approach for Correlation/Validation of Hot-Soak Terminal Temperature of a Vehicle Cabin CFD Model

2013-01-085404/08/2013

A Design for Six Sigma (DFSS) statistical approach is presented in this report to correlate a CFD cabin model with test results. The target is the volume-averaged hot-soak terminal temperature. The objective is to develop an effective correlation process for a simplified CFD cabin model so it can be used in practical design process. It is, however, not the objective in this report to develop the most accurate CFD cabin model that would be too expensive computationally at present to be used in routine design analysis. A 3-D CFD model of a vehicle cabin is the central part of the computer modeling in the development of automotive HVAC systems. Hot-soak terminal temperature is a thermal phenomenon in the cabin of a parked vehicle under the Sun when the overall heat transfer reaches equilibrium. It is often part of the simulation of HVAC system operation. The strategy in our design process is to use a simplified CFD cabin model correlated with available test results for rapid routine

Ye, Tao

Use of DFSS Principles to Develop an Objective Method to Assess Transient Vehicle Dynamics

2013-01-070804/08/2013

This paper presents subjective and objective methods for evaluating transient vehicle dynamics characteristics in four sections: (1) Definition of transient behavior in terms of four traits-agility, stability, precision, and roll support; (2) Description of subjective evaluation methods; (3) Implementation of Design for Six Sigma principles to the development of a steering robot controlled objective test for transient performance; (4) The final section of this paper uses data from simulation and road tests to demonstrate how chassis design parameters can affect transient handling performance.

Badiru, Ibrahim A., Neal, Michael W.

Robust Analytical Methodology for Hood Overslam Travel using a DFSS Approach

2013-01-138804/08/2013

Developing a robust model that can simulate all real world conditions a vehicle can experience can be extremely difficult to predict. When working through the engineering process, Computer Aided Engineers (CAE) traditionally set modeling parameters and conditions to a nominal setting. This is done to simplify the models so that it avoided inputting too much tedious details into the system and wasting so much engineering time preparing the work. It was soon realized that this strategy did not capture all the possible conditions a hood on a vehicle could experience. There was a need to develop a formal approach and method to correlate an analysis model to real world conditions. The Design for Six Sigma (DFSS) process was utilized to develop robustness in the techniques used to accurately understand the vehicle environment. The DFSS process is normally used to design and develop robustness into physical parts. This project took a different approach by applying the techniques in a virtual

Nallapati, Sankar Rao, Miller, Jason, Chinta, Balakrishna, Morley, John

Methodology for Design Simulation and Experimental Validation of High Temperature Enhanced Flow Materials in Automotive Lighting Bezel Applications

2013-01-137204/08/2013

The automotive lighting industry continues to optimize the balance between heat performance and cost performance for exterior lighting components. Headlamp bezel applications, in particular, must meet stringent heat and aesthetic requirements while delivering a part that meets cost and mass needs. This drive is inspiring the development of next generation, enhanced flow, high heat materials as well as the need for accurate processing prediction. Process simulation is one of the best tools to be leveraged at the design phase for evaluating optimization opportunities. The objective of this paper is to present the novel methodology of design simulation and experimental validation with six sigma concepts.

N, Venkatesha

Modification of a Plant's Engine Assembly Line to Reduce Employee Movement and Increase Productivity

2012-36-021810/02/2012

Modification of the workstations of the automaker engine assembly line in the Betim/MG unit, with a focus on ergonomics, reducing employee movement during the implementation of activities by eliminating activities that do not add value to the product. The entire project was structured according to WCM (World Class Manufacturing) methodology that consists of concepts, principles and techniques for managing operational processes, inspired by the Toyota Production System (TPS), which focuses on wastage elimination. The WCM is supported by technical and management pillars and the one used in this study was the WO (Workplace Organization) that seeks to create an ideal workplace to achieve maximum safety, improved quality, and maximum value in product transformation. The premise for the development of the solutions was the minimum use of resources, prioritizing simplicity of the devices by applying concepts of low cost automation (LCA) leaving the material near the assembling point. The

Sousa, Sergio Marcio, Araujo, Mario Lucio, Fonseca, Aline da Cassia, Nascimento, Silvano Weslley, Sousa, Marcos Cesar

Monitoring of International Space Station Telemetry Using Shewhart Control Charts

TBMG-1486610/01/2012

Shewhart control charts have been established as an expedient method for analyzing dynamic, trending data in order to identify anomalous subsystem performance as soon as such performance would exceed a statistically established baseline. Additionally, this leading indicator tool integrates a selection methodology that reduces false positive indications, optimizes true leading indicator events, minimizes computer processor unit duty cycles, and addresses human factor concerns (i.e., the potential for flight-controller data overload). This innovation leverages statistical process control, and provides a relatively simple way to allow flight controllers to focus their attention on subtle system changes that could lead to dramatic off-nominal system performance. Finally, this capability improves response time to potential hardware damage and/or crew injury, thereby improving space flight safety.

Optimized Caliper Design for Low Drag Using DFSS Method

2012-01-183509/17/2012

Limiting residual drag torque and fluid displacement is a major requirement of a caliper brake as they are related to the fuel efficiency and the safety of a vehicle. However, it is difficult to simultaneously reduce both the drag torque and the fluid displacement since improving one tends to degrade the other. This paper investigates a caliper with a high residual drag torque. DFSS (Design for Six Sigma) method was implemented to identify all major factors and the design optimization was performed to achieve a low drag caliper. The prototype was created with the desirable design factors identified in the study and the dynamometer tests confirmed that it is possible to achieve a low drag caliper without sacrificing the fluid displacement.

Kim, Junghan, Ryu, Namyeul, Kim, Youngtaek

Critical Success Factors of Lean Manufacturing Implementation in Automotive Industry in China

2012-01-051604/16/2012

Purpose - This research aimed to investigate the process of lean manufacturing implementation in automotive industry in China in order to identify the critical success factors. Design/methodology/approach - A review of relevant literature is used to identify potential critical success factors for lean manufacturing implementations. The research had targeted lean-manufacturing management, practitioners, process users, and consultants working in automotive industry in China. Data were collected with an electronic survey which included 20 close ended questions, each measured by using five-point scale, Out of total 200 questionnaire distributed, 80 useable responses were received resulting in 40 % response rate. A judgmental sampling technique had been selected. Both descriptive and inferential statistics had been used to analyze this data. Findings - Our findings indicated that the belief among the respondents that management engagement, communication, training, monitoring progress among

El Safty, Shady Baher

Making Six Sigma a Cultural Norm

2012-01-051304/16/2012

A common hurdle to enterprise-wide implementation of Six Sigma projects is the need to prepare employees so they are able to use statistical tools and graphical analysis techniques. Six Sigma deployment plans are replete with classes, seminars and coaching sessions aimed at the use and application of statistical procedures. Master Black Belts, Black Belts and external consultants are engaged in developing tutorial aids, analysis macros, and automated analysis routines so employees do not have to know too much to get the job done. A long term solution to this problem is to work with education providers and help them understand the industry's need for a better prepared work force. People who graduate from engineering, business and management programs need to be equipped with work-ready skills so they can make immediate contributions in the workplace. This paper and presentation describes the work two Six Sigma Master Black Belts have done to drive to the very root cause of this issue

Miller, Lisa, Frimenko, Jacob

Secrets for Successful Six Sigma Deployment

2012-01-051504/16/2012

This paper presents a system of factors that sometimes contribute to meager returns for Six Sigma deployment investments. The author shows how these factors erode improvement project efficiency and describes program strategies that are effective counter measures. Solutions included: keeping business leaders responsible for improvements, using expert project coaches, sharing and replicating project findings and lessons, reducing project burden, focusing on improvement projects, and using concentrated and time-bound efforts.

Frimenko, Jacob

The Role of Design for Six Sigma in Successful Product Development

10VARANN1812/21/2011

Successful product development (PD) includes understanding and delighting customers, anticipating and avoiding failures, and delivering products efficiently. While Design for Six Sigma may be most naturally applied to avoid failures, it has been applied to all three of these areas with varying degrees of success. This paper discusses the advantages and disadvantages of using DFSS to bolster these key elements of PD. Example projects along with successes and shortcomings related to overall PD effectiveness are presented. Whatever form DFSS takes, organizations should make explicit the decision of how to deploy DFSS as part of an overarching quality plan. Presenter Nathan Soderborg, Exponent Inc.

Soderborg, Nathan

Hydraulic Hybrid System Optimization Using Design For Six Sigma

11VCV5010312/05/2011

There are several variables to consider when specifying a hydraulic hybrid system in a commercial vehicle. Parameters which can be controlled include various component sizes and some hybrid system calibration parameters. Presenter Paul Schwark, Bosch Rexroth AG

Schwark, Paul

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