• Join over 1.2 million students every month
  • Accelerate your learning by 29%
  • Unlimited access from just £6.99 per month

Six sigma methology for solving automotive engineering problems.

Extracts from this document...

Introduction

SIX SIGMA METHODLOGY FOR SOLVING AUTOMOTIVE ENGINEERING PROBLEMS ABSTRACT All engineering problems are dependent on multiple design variables and the solutions for these needs to satisfy different responses. Compromises in deciding values for these design variables need to be made so that all the functional requirements are met with in the budgeted cost and time. To arrive at the values for these design variables, there is a need to understand the main and interaction effects of all these input parameters on the response variables and hence, necessitates conducting scores to hundreds of experiments. Performing these numbers of experiments may not be feasible every time given the budget and cost constraints. Methods like DoE based on statistical basis are found useful in such scenario where the effects of all the input parameters are modeled with a minimum number of experiments. Application of mathematical tools to engineering problems poses several challenges in arriving feasible solutions and DoE is no different. This article describes the challenges that are faced in applying DoE to automotive engineering problems. A six-sigma based methodology thus arrived based on how these challenges were overcome with two case studies is presented in this article. Key Words: Design of Experiments, Response Variable, Automotive Seating System 1. Introduction The crucial factors that govern engineering and design of automotive systems are safety and cost. Several specifications, Legal and Customer specified, that guide the design of the systems from package and strength points of view need to be satisfied in designing these systems. Automotive Seating Systems also play a major role in providing safety to the passengers apart from satisfying other important requirements like comfort. ...read more.

Middle

Even though in the present problem, the length of the ground link, L4 is fixed, it has been varied along with the A, the angle of the front link in Design configuration for getting the required travel. Thus, four response variables are defined that are to be calculated from the simulation experimentation viz. Link Length Ratio ?, the ratio of the length of the Ground Link to that of the Intermediate Link, H-X, the H-point travel in X-direction when the mechanism is in High configuration, H-L, the H-point travel in X-direction when the mechanism is in Low configuration and angle A. From simple reasoning it can be deduced that for an efficient design angle A should be approximately equal to 45� and ? should be approximately equal to unity. Based on these conditions, the problem is stated mathematically as given in Table. 1. Figure 3. Travel of H-Point in Design, Low and High Configurations Figure 4. Constrained Wire-frame used in the study Table 1. Variable Definitions for Lift Mechanism Problem Input Variables Front Link Length, L1 Rear Link Length, L3 Inter-mediate Link Length, L2 Range to be included Response Variables H-Point travel along negative X-axis, H-X H-Point travel along positive X-axis, H+X Traverse angle, A Link Length Ration, ? NA Optimization Criteria 1. Maximize H-X 2. Maximize H+X 3. Target A ~ 45� 4. Target ? ?1 NA 3.1.3 Six-Sigma Three six-sigma tools - Design of Experiments, Regression and Optimization have been used in the present problem. The inputs with their possible ranges in levels of 3 has been considered and been fed into the six sigma tool so that a set of full factorial experiments to be conducted are designed. ...read more.

Conclusion

The results that are obtained from the simulation run show a close agreement between the values obtained from the Regression output confirming the validity of the exercise (Refer Table. 6). Table 6. Comparison between the Results obtained by solving Regression equations and from Simulation Run Sl. No. Output Parameter Results obtained by solving Regression Equations Results obtained from Simulation run 1 Percentage Plastic Strain in Front Inboard Foot 28 25 2 Percentage Plastic Strain in Front Outboard Foot 34 35 3 Percentage Plastic Strain in Rear Inboard Foot 23 25 4 Deflection of Seat back in X 405.3 410 5 Deflection of Seat back in Z - 341.5 -360 4. Discussion and Conclusion It has been evident from the two case studies that Six- Sigma tools have a definite applicability in the automotive engineering problems when proper transformations in converting the practical problem into a mathematical one for optimized solution. Also, the importance of these tools can be found in hitting the targets more precisely with in the ambit of the posed constraints. As there is no definite possibility in case of the problem described in the first case study, that one will hit the target with trial and error methods, application of such tools becomes inevitable. Moreover, tools like Design of Experiments help in achieving higher productivity, which is an important requirement for present day's corporations to maintain the competitive edge. 5. Acknowledgements The authors gratefully acknowledge the review efforts spent by Dr. M.S.S. Prabhu, Mr. Padmanabhan Venkataraman, Mr. M.R. Ravishankar, Mr. Hursh Kumar Donde and Mr. Ramanath, K.S. in finalizing the methodology proposed in the present article and in validating the case studies. ...read more.

The above preview is unformatted text

This student written piece of work is one of many that can be found in our GCSE Resistant Materials section.

Found what you're looking for?

  • Start learning 29% faster today
  • 150,000+ documents available
  • Just £6.99 a month

Not the one? Search for your essay title...
  • Join over 1.2 million students every month
  • Accelerate your learning by 29%
  • Unlimited access from just £6.99 per month

See related essaysSee related essays

Related GCSE Resistant Materials essays

  1. Metallography. The objective of our experiment is to learn specimen preparation techniques in metallography ...

    The different etching procedures can be classified into the nondestructive techniques, which do not alter the surface (optical etching), and destructive methods, which induce surface damage (chemical and physical etching). All of these processes play in integral role in the metallographic process.

  2. DESIGN OF A TIMBER PORTAL FRAME STRUCTURE

    It involves inputting the extreme design calculations to simulate the behaviour of the portal frame and then obtaining the bending moments and shear forces under these calculated loads. With the equation (?M = ?K1 K4 K6 K9 K11 K12 Fb'Z)

  1. Investigate and evaluate the differences and similarities in the key features in planning the ...

    The backrest should include a lumbar support, this lumbar support helps reduce the pressure on the spine and the backrest should include a tilt action. The chair also must implement armrests, which should be at least 2 inches wide to provide support for the arms.

  2. Communication of Safety In the Design Phase.

    In relation to the design process, Latham noted that "effective management of the design process is crucial for the success of the project". Lack of sufficient management during the design phase results in insufficient information for completing designs or resolving conflicting construction details.

  1. Communication: the Key To Designing Safely.

    and The Consultancy Company Report (HSE 1997). They found that many designers are unsure of their duties and the extent of risk assessment required and that as a result, the practices of designers are affected by their lack of familiarity with the requirements.

  2. Free essay

    Product & Design

    In this case I would use something such as pro desktop or another piece of software that allows 3D design. This would make the process quicker and easier as every single measurement will be accurate to a tenth of a millimetre.

  1. EFFECT OF MOISTURE ON THE MECHANICAL PROPERTIES OF NYLON

    NYLON 66,69,610,& 612 The Nylon 66 salt is prepared by reacting the hexamethylenediamine and adipic acid in boiling methanol, the comparatively in soluble salt (melting point 190-191*C) precipitating out. A 60% aqueous solution of the salt is then run in to a stainless steel autoclave together with a trace of acetic acid to limit the molecular weight (9000-15000).

  2. 3. In what ways do the material conditions of city life shape and inform the ...

    so she is relating the material conditions of the city with her emotions and giving the reader an image of doom and gloom within the city. Although the material conditions described to us previously in the novel have been mostly doom and gloom anyway, Nazneen has only just implied the greyness and dullness of it along with her emotions.

  • Over 160,000 pieces
    of student written work
  • Annotated by
    experienced teachers
  • Ideas and feedback to
    improve your own work