Design of Experiments (DOE) and Other 6-Sigma Tools Used to Minimize Rear Door Opening Vibration on a Vehicle

Very often, engineering problems involve several variables that have different physical behavior making theoretical modeling complex and difficult. In the present paper, 6-Sigma tools were used to develop an experimental model that describes the system. The issue in focus was the vibration observed at the top of rear door during normal opening operation, causing the impression of a fragile structure. The resulting experimental model was able to explain door opening vibration with only 15% of error. In addition, it was possible to choose the best combination and setting for each variable in order to achieve a product benchmarking value.