Failure modes and effects analysis (FMEA); Reliability; Product Development; Design Process; Test Procedures "Explore Product Design and Testing for Automotive Engineering: Volume II, an essential guide reshaping vehicle manufacturing with unprecedented reliability. As part of SAE International’s DOE for Product Reliability Growth series, this practical resource introduces cutting-edge methodologies crucial for predicting and improving product reliability in an era of automotive electrification. The book navigates statistical tolerance design, showcasing how variability in part fabrication and assembly can enhance reliability and sustainability. Key topics include: - Statistical tolerance design's impact on manufacturing and material selection, focusing on non-normal distributions' effects on product assembly and cost. Methods like maximum likelihood estimators and Monte Carlo simulations are used for assembly strategy synthesis. - Reliability DOEs using log-location-scale distributions to estimate lifetimes of non-normally distributed components, especially in accelerated life testing. It covers transformations optimizing parts and system designs under the lognormal distribution. - Weibull distribution (DOE-W) for characterizing lifetimes affected by various failure modes, detailing parameter assessment methods and real-world applications. The book also introduces reliability design of experiments based on the exponential distribution (DOE-E). - Importance of predicting lifecycles and enhancing reliability through qualitative and stepwise accelerated life tests. Integration of physics of failure with statistical methods like Weibull statistics and lognormal approximation enhances analysis credibility. - Inferential mechanisms such as the Arrhenius and Eyring models in predicting automotive component lifecycles, refining product life prediction based on reliability DOEs. Whether you're an engineer, researcher, or automotive professional, this book equips you to navigate reliability engineering confidently. Revolutionize your approach to product design and testing with Product Design and Testing for Automotive Engineering, your definitive companion in shaping the future of automotive reliability." (ISBN 9781468607703 ISBN 9781468607697 ISBN 9781468607727 DOI 10.4271/9781468607697)

In a world where innovation and sustainability are paramount, Fundamentals of Design of Experiments for Automotive Engineering: Volume I serves as a definitive guide to harnessing the power of statistical thinking in product development. As first of four volumes in SAE International’s DOE for Product Reliability Growth series, this book presents a practical, application-focused approach by emphasizing DOE as a dynamic tool for automotive engineers. It showcases real-world examples, demonstrating how process improvements and system optimizations can significantly enhance product reliability. The author, Yung Chiang, leverages extensive product development expertise to present a comprehensive process that ensures product performance and reliability throughout its entire lifecycle. Whether individuals are involved in research, design, testing, manufacturing, or marketing, this essential reference equips them with the skills needed to excel in their respective roles. This book explores the potential of Reliability and Sustainability with DOE, featuring the following topics: - Fundamental prerequisites for deploying DOE: Product reliability processes, measurement uncertainty, failure analysis, and design for reliability. - Full factorial design 2K: A system identification tool for relating objectives to factors and understanding main and interactive effects. - Fractional factorial design 2RK-P: Ideal for identifying main effects and 2-factor interactions. - General fractional factorial design LK-P: Systematically identification of significant inputs and analysis of nonlinear behaviors. - Composite designs as response surface methods: Resolving interactions and optimizing decisions with limited factors. - Adapting to practical challenges with “short” DOE: Leveraging optimization schemes like D-optimality, and A-optimality for optimal results. Readers are encouraged not to allow product failures to hinder progress but to embrace the "statistical thinking" embedded in DOE. This book can illuminate the path to designing products that stand the test of time, resulting in satisfied customers and thriving businesses. (ISBN 9781468606027, ISBN 9781468606034, ISBN 9781468606041, DOI 10.4271/9781468606034)

In a world where innovation and sustainability are paramount, Fundamentals of Design of Experiments for Automotive Engineering: Volume I serves as a definitive guide to harnessing the power of statistical thinking in product development. As first of four volumes in SAE International’s DOE for Product Reliability Growth series, this book presents a practical, application-focused approach by emphasizing DOE as a dynamic tool for automotive engineers. It showcases real-world examples, demonstrating how process improvements and system optimizations can significantly enhance product reliability. The author, Yung Chiang, leverages extensive product development expertise to present a comprehensive process that ensures product performance and reliability throughout its entire lifecycle. Whether individuals are involved in research, design, testing, manufacturing, or marketing, this essential reference equips them with the skills needed to excel in their respective roles. This book explores the potential of Reliability and Sustainability with DOE, featuring the following topics: - Fundamental prerequisites for deploying DOE: Product reliability processes, measurement uncertainty, failure analysis, and design for reliability. - Full factorial design 2K: A system identification tool for relating objectives to factors and understanding main and interactive effects. - Fractional factorial design 2RK-P: Ideal for identifying main effects and 2-factor interactions. - General fractional factorial design LK-P: Systematically identification of significant inputs and analysis of nonlinear behaviors. - Composite designs as response surface methods: Resolving interactions and optimizing decisions with limited factors. - Adapting to practical challenges with “short” DOE: Leveraging optimization schemes like D-optimality, and A-optimality for optimal results. Readers are encouraged not to allow product failures to hinder progress but to embrace the "statistical thinking" embedded in DOE. This book can illuminate the path to designing products that stand the test of time, resulting in satisfied customers and thriving businesses. (ISBN 9781468606027, ISBN 9781468606034, ISBN 9781468606041, DOI 10.4271/9781468606034)

This book is about how to develop future automotive products by applying the latest methodologies based on a systems engineering approach and by taking into account many issues facing the auto industry such as meeting government safety, emissions and fuel economy regulations, incorporating advances in new technology applications in structural materials, power trains, vehicle lighting systems, displays and telematics, and satisfying the very demanding customer. It is financially disastrous for any automotive company to create a vehicle that very few people want. To design an automotive product that will be successful in the marketplace requires carefully orchestrated teamwork of experts from many disciplines, substantial amount of resources, and application of proven techniques at the right time during the product development process. Automotive Product Development: A Systems Engineering Implementation is intended for company management personnel and graduate students in engineering, business management and other disciplines associated with the development of automotive and other complex products.

The overall goal of vehicle design is to make a robust and reliable product that meets the demands of the customers and this book treats the topic of analysing and describing customer loads with respect to durability. Guide to Load Analysis for Vehicle and Durability Engineering supplies a variety of methods for load analysis and also explains their proper use in view of the vehicle design process. In Part I, Overview, there are two chapters presenting the scope of the book as well as providing an introduction to the subject. Part II, Methods for Load Analysis, describes useful methods and indicates how and when they should be used. Part III, Load Analysis in view of the Vehicle Design Process, offers strategies for the evaluation of customer loads, in particular characterization of customer populations, which leads to the derivation of design loads, and finally to the verification of systems and components. Key features: • Is a comprehensive collection of methods for load analysis, vehicle dynamics and statistics • Combines standard load data analysis methods with statistical aspects on deriving test loads from surveys of customer usage • Sets the methods used in the framework of system dynamics and response, and derives recommendations for the application of methods in engineering practice • Presents a reliability design methodology based on statistical evaluation of component strength and customers loads • Includes case studies and illustrative examples that translate the theory into engineering practice Developed in cooperation with six European truck manufacturers (DAF, Daimler, Iveco, MAN, Scania and Volvo) to meet the needs of industry, Guide to Load Analysis for Vehicle and Durability Engineering provides an understanding of the current methods in load analysis and will inspire the incorporation of new techniques in the design and test processes.

Front Cover -- Title Page -- Copyright Page -- Contents -- Preface -- Acronyms -- Nomenclature -- Introduction -- Chapter 1: Reliability Deployment -- 1.1 Product Reliability Realization -- 1.1.1 Product Quality, Robustness, and Reliability -- 1.1.2 Realization Process of Product Reliability -- 1.1.3 Tools for Reliability Realization -- 1.1.4 Advanced Reliability Planning -- 1.1.5 Reliability Lauded in VOC -- 1.1.6 Product Reliability Growth -- 1.2 Uncertainty of Measurement -- 1.2.1 Accuracy: Precision and Trueness -- 1.2.2 Essential Elements of Measurement -- 1.3 Unreliability -- 1.3.1 Physical and Functional Failures -- 1.3.2 Probability of Product Failure -- 1.3.3 Failure Measured by Time -- 1.4 Design for Reliability -- 1.4.1 Reference Model and Simulation for System Identification -- 1.4.2 Boundary Diagram -- 1.4.3 Parameter Diagram (P-Diagram) -- 1.4.4 Fishbone Diagram -- 1.4.5 Variation Modes and Effect Analysis -- 1.5 Classification of DOE -- 1.5.1 Basic Types of DOE -- 1.5.2 Acceptance Sampling and Test Plans -- 1.5.3 Statistical Tolerance Design -- 1.5.4 Manufacturing Reliability -- 1.5.5 Supply Chain Reliability -- 1.5.6 Operational Reliability -- 1.5.7 Marketing Reliability -- 1.5.8 Holistic Approach -- 1.6 Software for DOE -- References -- Chapter 2: Full Factorial Design 2 K -- 2.1 Why DOE -- 2.1.1 Complete Search for Solution in the Multidomain -- 2.1.2 Tremendous Reduction in the Number of Experimental Tests -- 2.2 What Is DOE -- 2.2.1 Application for DOE -- 2.2.2 Experimental Design Process -- 2.2.3 History of DOE -- 2.3 Objective Function and Goals -- 2.3.1 Quantifiable and Achievable -- 2.3.2 RSM: Regression Using DOE -- 2.4 Factors -- 2.4.1 Types of Factors -- 2.4.2 Effects of Factors and Their Interactions -- 2.4.3 Selections-Doable and Controllable -- 2.4.4 Dimensionless Format -- 2.4.5 Design Contrasts and Effects.