Browse Topic: Six Sigma

Items (132)

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

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

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.

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

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

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

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

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

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.

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

Reducing Energy Use in Aircraft Component Manufacture - Applying Best Practice in Sustainable Manufacturing

2011-01-273910/18/2011

Rising energy costs and increased regulation in recent years have caused industrialists to investigate how to apply ‘energy efficiency’ to their manufacturing operations. As well as reducing operating costs, the benefits of a ‘green’ image as a market differentiator are beginning to be realised. The literature describes the successful implementation of a variety of approaches to energy reduction, with particular focus on energy intensive industries (such as foundries) and on improvements to building services (such as lighting). However, a systematic approach to applying sustainable practices to the manufacturing processes involved in the production of high value products, such as aircraft, is noticeably absent. This paper describes how a number of sustainable manufacturing approaches have been combined, enhanced and applied to the shop floor of a manufacturing facility in the UK responsible for the production of large component assemblies for the aerospace industry. The focus is on

Lunt, Peter, Levers, Andrew

Effects of Fretting Corrosion on Lift Glass

2011-01-143404/12/2011

The electrical architecture design of a rear back glass defrost grid system encompasses many critical criteria that must be integrated into the design. For example, the defrost clip location and interface to the glass must meet all vehicle performance requirements. If the defrost clip to the glass interface is not resistant to vibration and relative movement, detachment and loss of function can occur. This paper describes a back glass defrost clip with a solder joint that is robust to manufacturing variations and customer usage conditions. A designed experiment using Design for Six Sigma methodologies was performed to understand the effects of the attachment interface to the electrical wiring pigtail, and parameters that affect performance. The working constraints, testing set up, validation, and root cause investigation of the clip detachment phenomenon is covered in this paper.

Pyszel, Richard

A Structured Approach for Function Analysis of Complex Automotive Systems

2011-01-126804/12/2011

Function analysis provides the backbone of systems engineering design and underpins the use of Design for Six Sigma and Failure Mode Avoidance tools. Identification and management of interfaces is a key task in systems engineering design, in ensuring that the system achieves its functions in a robust and reliable way. The aim of the work presented in this paper was to develop and implement a structured approach for function analysis of a complex system, which focuses on the identification and characterization of interfaces. The proposed approach is based on the principle of separation of the functional and physical domains and development of function decomposition through iteration between functional and physical domains. This is achieved by integrating some existing / known engineering tools such as Boundary Diagram, State Flow Diagram, Function Tree and an enhanced interface analysis within a coherent flow of information. The approach is illustrated with a case study on system level

Campean, Ioan F., Henshall, Edwin, Brunson, David, Day, Andrew, McLellan, Rod, Hartley, Joseph

Innovative Robust Solutions for Lean Manufacturing in Automotive Assembly Processes

2011-01-125404/12/2011

The article presents an innovative approach to the implementation of a robust design optimization solution in an automobiles assembly process. The approach of the entire project is specific to the 6 Sigma optimization process, by applying the DMAIC cycle integrated in a robust engineering approach for rendering lean the final product assembly process. According to the improvement cycle, the aspects specific for such a process are presented sequentially starting with the “Define” phase for presenting the encountered problem and continuing with the presentation of the scope of the project and its objectives. The “Improvement” cycle phase is applied by the analysis of the monitored 6 Sigma metrics (defined during the previous “Measure” phase and the cause and effect analysis, done during a brainstorming meeting developed during the “Analyze” phase). There follows a proposal for the innovative robust solution by which the assembly process is optimized. Therefore, we propose the final

Negrus, Andrei Mihai, Mihail, Laurentiu Aurel, Chiru, Anghel

Critical Success Factors of Six-Sigma Implementation in Automotive Industry in Egypt

2011-01-127004/12/2011

Purpose - This research aimed to investigate the process of six-sigma implementation in automotive industry in Egypt in order to identify the critical success factors. Research design and methodology - A review of relevant literature is used to identify potential critical success factors for six-sigma implementations. The research had targeted six-sigma management, practitioners, process users, and consultants working in automotive industry in Egypt. Data were collected with an electronic survey which included 20 close ended questions, each measured by using five-point scale, Out of total 600 questionnaire distributed, 240 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 are critical success factors

El Safty, Shady Baher

Process Automation Wizard for Vehicle Dynamics Applications

2011-01-074004/12/2011

The imperative to get to the market faster with new and better products, has determined all automotive OEM to rethink their product development cycle, and, as a result, many hardware based processes were replaced and/or augmented with virtual, software based ones. However, the virtualization itself does not guaranties better and faster products. In the area of vehicle dynamics, we concentrate on improving the multi-body model development process, facilitating comprehensive virtual testing, and verifying the robustness of the design. The authors present a highly flexible and efficient environment that encourages, enforces, and facilitates model sharing, reusing of components, and parallelization of vehicle dynamics simulations, developed on top of an existing commercial off-the-shelf engineering software application.

Buzdugan, Laurentiu, Liang, Cwo Gee

Use of Six Sigma to Move Verification of Vehicle Remote Keyless Entry Upstreams in Product Development Process

2010-01-070104/12/2010

A primary goal within the industry is to shorten the lead time to get shorter time to market and lower cost. System verification can set the limits for how short the lead time can be. Traditionally verification of automotive communication systems like Remote Keyless Entry, RKE, is performed in a complete vehicle late in the product development process. To fulfill the quality demands during the shorter project time Volvo Cars, VCC, has experienced that it is necessary to develop new requirements and verification methods. Six Sigma contains a complete toolbox to do this in a structured and time efficient way. VCC has together with other Ford Motor Company, FMC, brands and the supplier Continental developed methods and requirements so that the RKE system can be verified before vehicles are built. Only a last validation has to be performed in a complete vehicle. The process consists of: Well defined technical requirements on the transceiver and key fob modules that can be verified in a

Bergqvist, Bjorn M., Nilsson, Mikael, Jiresten II, Dan

Sphere-To-Cone Mating – New Solution to Improve Brake Tube Connector Sealing Robustness

2009-01-302410/11/2009

Recently invented solutions (Canadian Patent 2593305 and United States Patent Applications 20090015008 and 20070194567) incorporate sphere-to-cone type of the interaction between sealing surfaces in a brake tube connector. An interaction of sphere-to-cone type has numerous advantages over one with a cone-to-cone type which is currently utilized in conventional automotive brake tube connectors. Incorporation of a sphere-to-cone interaction between the sealing surfaces dramatically improves connector's sealing robustness. Sphere-to-cone based connectors are resilient to the tube and seat axes misalignment. Correspondingly, sphere-to-cone based connectors have less variation of the securing torque and virtually no propensity to locked misalignment occurrence. The article analyzes another fundamental advantage of a sphere-to-cone mating over the conventional cone-to-cone one. The analysis reveals that sphere-to-cone type of interaction demonstrates approximately one order of magnitude (10

Pliassounov, Stanislav I.

Achieving Breakthrough on Manufacturing Floor through Project-Based Organization

2009-36-033310/06/2009

Many companies around the world have adopted the lean thinking as their strategy to operate, in a global market where changes happen all the time. One foundation for the success of lean manufacturing appliance is the continuous improvement approach which has been considered even on company statements, or it can be also considered as part of the genetic code of any enterprise. However, if in one side the continuous improvement thinking, set people mind to look for opportunities of improvement all the time, on other hand these improvements are incremental and they do not have significant impact on company performance on both short-term and medium-term and sometimes, the activities performed by the employees are not sustainable due to the lack of structure to manage and follow up these activities. Therefore, based on lean manufacturing concept, this paper has per its main purpose to discuss and make a proposal of an project-based manufacturing including the development of core

Júnior, Joel da Conçeião

Analysis of Butane Diffusion in Activated Carbon Canister

2009-01-097604/20/2009

A canister filled with activated carbon prevents the emission of hydrocarbon into the air, through repeated adsorption and desorption process. A small amount of hydrocarbon, with n-butane as one of the major components, remains inside the canister. The diffusion of this residual n-butane affects Diurnal Breathing Loss performance. This study reports the quantitative difference of n-butane diffusion and breakthrough under three experimental conditions. Furthermore, diffusion speed, which is an important factor in the analysis of canister performance and the design development of canister, was also calculated.

Yamasaki, Koji, Suzuki, Tsugio, Sato, Kazunari, Kobayashi, Noriyuki, Tanaka, Hiroyuki, Endo, Hiroshi

Robust Analysis of Clamp Load Loss in Aluminum Threads due to Thermal Cycling

2009-01-098904/20/2009

A DFSS study identified a new mechanism for clamp load loss in aluminum threads due to thermal cycling. In bolted joints tightened to yield, the difference in thermal expansion between the aluminum and steel threads can result in a loss of clamp load with each thermal cycle. This clamp load loss is significantly greater than the loss that can be explained by creep alone. A math model was created and used to conduct a robust analysis. This analysis led to an understanding of the design factors necessary to reduce the cyclic clamp load loss in the aluminum threads. This understanding was then used to create optimized design solutions that satisfy constraints common to powertrain applications. Estimations of clamp load loss due to thermal cycling from the math model will be presented. The estimates of the model will be compared to observed physical test data. A robust analysis, including S/N and mean effect summary will be presented.

Bartnick, Brian K., Shea, David H., Weed, Dean L.

The Study on New Product Designing Method by Using TRIZ

2009-01-098804/20/2009

After era of productivity and quality, creativity is considered as an important issue to become winner and build paradigm in the global market. In the past, brainstorming based on inspiration and experience was the most popular method for accelerating creativity in R&D process. But if there is more efficient and powerful method similar to mathematical formula instead of trial & error, the productivity of creation could be increased dramatically. TRIZ (Theory of Inventive Problem Solving) can be a powerful method of innovation. It is developed by Russian scientist, Genrich Altshuller since from 1950s. He found pattern and laws for problem solving and technical evolution through investigation of millions of patent and innovation cases. Like mathematics, every technical problem can be changed to simplified model and every model has its own model of solution. Because TRIZ is inductive theory, the solution model has its own real practices. TRIZ can be sometimes used combined with Axiomatic

Kang, Young-Ju

Application of Six Sigma methodology on reducing the noise level on alternators

2008-36-032710/07/2008

The environment waits from the technology, a contribution to reduce energy consumption, emissions, natural resources, keeping the focus on the costumer's comfort. In this way, we highlight in this work, a development/study oriented for the noise reduction on alternators (aerodynamic noise). Using the Six Sigma methodology, we have studied all factors that could generate aerodynamic noise, through statistical tools and analysis. A development with a new technology and electrical lay-out is necessary to reduce magnetic noise. This work allowed to improve the product and moves the noise emission to a more comfortable level.

Pinto, Celso Antonio Dias, Dias, Daul, Walter, José

Capability prediction through Design of Experiments (DOE) and Monte Carlo Simulation on Automotive Innovation Activities

2008-36-002110/07/2008

Nowadays Design of Experiments (DOE) has been used intensively in industrial environment as an important tool to identify critical factors related to a certain output characteristic. Another relevant characteristic is that the DOE can also be used as a strong resource on “physical system modeling process”, as presented in this paper. It was possible to generate a transfer function relating the output and the main input factors and in sequence a Monte Carlo simulation was used in order to predict the process capability. It was possible to observe a strong convergence between predicted results and real world results.

Junior, Helio Maciel, Turrioni, João Batista, Mologni, Juliano Fujioka, Fernandes, Marcelo Machado

Screening of key contributors through BLR utilization - a specific transmission noise claim case study

2008-36-008610/07/2008

This paper illustrates one example where Six Sigma was applied to identify, through a screening process using BLR (binary logistic regression), the main contributors to transmissions presenting a 2nd gear whine noise condition. With the help of Six Sigma and its Binary Logistics Regression (BLR) tool, the process was optimized through the minimization of the variation of the main contributors to the noise claim in question. The Binary Logistic Regression (BLR) is a statistical technique for making predictions used when an attributive analysis is carried out. In this case study such a statistical tool was used as the issue followed a subjective analysis.

Filho, Lourival Stradiotti

Contests of Projects as Agents of Motivation and Continuous Improving Process: A Case Study at an auto parts manufacturer

2008-36-001910/07/2008

The Contest is a corporate process that has several goals: To initiate outstanding performances within all areas, contributing to sustainable customer satisfaction, encouraging and supporting a continuous improvement process, stimulating an exchange of experiences within the group to learn better from each other. The Contest honors projects: which demonstrate an improvement regarding leadership, strategy, people motivation, partnerships & resources, processes, customer satisfaction, environmental protection or financial results which provide measurable improvements and do not date back for more than one year which are completed and show successful results, or at least are in deployment/implementation phase and show first successful results whose project content may be allowed to be shared with others. The results must have measurable improvements with Cost/Benefit analysis and the achieved improvements previously defined as project goals. The Contest promotes Knowledge transfer

Avileis, Laercio, Mattos, Edson

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