• 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...


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.


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.


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. Free essay

    Product & Design

    much easier and better to hold and carry when or if needed. Construction I only used woodworking machines that I have been trained to use properly and safely. And always wore safety glasses or goggles. Wore dust masks when required.

  2. Explain Aristotle idea of the four causes.

    For example, the final cause of a statue could be to portray a goddess, to serve the gods, or, perhaps, to provide aesthetic utility. Similarly, the final cause of something like a house would be to provide shelter. Now that we have an understanding of Aristotle's four causes, let

  1. The task has been set to make a hole punch (used to punch holes ...

    The two processes are very similar - the words that are used show which material is to be kept and which is waste (blanking - kept, piercing - waste). Strips of metal are passed between a flat-faced hardened alloy steel punch and a matching 'die' hole.


    The pressure is then reduced to atmospheric for one hour, after which the polymer extruded by oxygen free nitrogen on to a water cool casting wheel, to form a ribbon, which is subsequently disintegrated. Nylon 610 is prepared from the appropriate salt (melting point 179*C)

  1. My aim of this experiment is to recognize which material is the greatest sound ...

    Further, I had made sure that when attaching each of the insulating layers together, that I used cello tape to stick each layer together so that they would not collapse once inside the box once inserting the CD player. To check this I rattled the box to see if I could hear any scuffling of the layers.

  2. Communication of Safety In the Design Phase.

    The Latham Report (1993) suggests clients must allow adequate time for the preparation of the brief and should seek advice. " Even the best clients are likely to benefit from some advice on alternative methods of achieving their aim, which may produce better value for money".


    They are shown below 1.35G...............................?M 26.45 KNm > M* 3.83 KNm 1.2G + 1.5Q........................?M 43.6 KNm > M* 10.28 KNm 0.9G + WU .........................?M 53.4 KNm > M* 29.4 KNm 5. Girts The timber girts are the wall sheeting rails.

  2. A new branch of a major Chinese take away, Wok In, is opening in ...

    Lowercase, or minuscule. 3. Point size: the measurement taken from the top of the k to the bottom of the g. 4. X-height: the overall height of the body of the lowercase letters. 5. Capital height: for use in capital alphabets.

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