F2008-12-204
Design for Six Sigma (DFSS) for an Automotive System Supplier
The expected result of an engineering organization that practices the disciplines of Robust Engineering in its "up-front" design process is near zero quality issues. The designs these teams engineer show a clear understanding of the customers expectations of function over varying usage conditions. The teams also comprehend the environmental and manufacturing noise factors, and the sub-systems interactions to deliver a robust product to the market place.
In the automotive sector, many engineered products are designed and manufactured by companies other than the original equipment manufacturer. Direct access to the voice of the customer is difficult, and understanding the interfaces and interactions of the complex vehicle system requires much support from the OEM. The supplier cannot alone depend on product specifications to rationalize the scope of this focused effort. A skilled work force and cross functional team between the two companies is necessary to deliver value from the robustness disciplines to the marketplace.
However, taking the limitations for suppliers into account, DFSS can also be used to improve or resolve robustness issues. This paper outlines the chosen approach of ArvinMeritor, as a typical first tier supplier of automotive roof system, to conduct such a DFSS project. Project selection, the development of robust engineering skills and the definition of a lean DFSS process for a small engineering organization are presented. As an example of this activity, the progress on a design of a manual sun shade with regard to its operation efforts is demonstrated.
Poster presentation: Simulation and testing