Abstract
Keywords: DFSS, Roof Systems, Robustness, Optimization, Automotive
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. These engineers possess a clear understanding of the customer's expectations of function over varying usage conditions. The teams also comprehend the environmental and manufacturing noise factors, and the part to part interactions within a functional system to deliver a robust product to the market place.
In the automotive sector, many products are designed and manufactured by companies other than the original equipment manufacturer. For first and second tier suppliers, direct access to the voice of the customer is difficult, and understanding the interfaces and interactions of the complex vehicle system usually requires support from the OEM.
However, taking supplier limitations of vehicle system knowledge and the lack of direct contact to end customers into account, DFSS can also be used to improve or resolve robustness issues within a sub-system. This paper outlines the chosen approach of ArvinMeritor, as a typical first tier supplier of automotive body systems, to implement a lean DFSS process. Organizational aspects, the development of robust engineering skills, project selection and the linkage of DFSS activities to the product development process are presented. As an example of this initiative, the progress on a design of a manual sun shade with regard to its operation efforts is demonstrated.