Abstract
Abstract
The Six Sigma approach in mass production processes is well known and undisputed. Single parts, complete components and whole systems are fabricated in high volume. Production data is therefore available in large quantity, so statistical methods can be easily used to analyse the attribute and variable data of current processes. Process and product improvements are implemented on the basis of these investigations. This paper describes how Six Sigma is extended to the Visteon Product Development Laboratories. The product development differs from the mass production process in that it has to develop innovative and robust products within a minimum of cost and time. In the automotive industry all technical decisions are based on test data. Within the first phases of a project the data is used for CAE correlation and performance prediction. As the project proceeds the test data is used for optimization, tolerance analysis and finally for product validation. Most prototype parts are expensive and only few parts are available. Only a few test results are therefore available for decision-making. So it is absolutely essential to have reliable test equipment and robust test methodologies. Within the Climate Control vehicle attribute product development process, extensive use in made of complex calorimeter test rigs. These rigs have a lot of significant inputs, which affect the final results. Even for such complex systems Six Sigma is shown to be a suitable method to continuously improve the test stand reliability.