Abstract
The purpose of this paper is to show the robust design procedure for the brake pad forming process and suspension bushing stiffness using DOE(Design of Experiments). The brake pad forming process was designed to reduce the variance and adjust the mean of the compressibility of the product to the target to reduce brake groan noise. The screening DOE was performed to find out the variance shifter. The main DOE was performed to adjust the mean with the variance shifter fixed at minimum variance condition. The improvement was verified by the process capability analysis and the hypothesis testing. As for example of the product robust design, the suspension bushing stiffnesses were designed to minimize the lateral acceleration at the steering wheel top point to reduce shimmy effects.