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DMAIC Root Cause Investigation for Crash Simulation Discrepancies

30 Chapters
View Course Samples Online
01
DMAIC framework for crash simulation discrepancies
Define phase scoping, project charter, and stakeholder alignment.
DMAICframework
02
Characterizing crash simulation discrepancies
types, sources, and impact on CAE-driven design decisions.
Characterizingsimulation
03
Define phase deliverables
problem statement, measurable CTQs, and boundary definition for simulation correlation projects.
deliverablesstatement
04
Measurement system analysis for crash simulation
validating solver outputs, instrumentation data, and correlation metrics.
Measurementanalysis
05
Data collection planning
DOE for simulation runs, run matrix design, and managing computational cost.
collectionplanning
06
Baseline capability assessment
quantifying discrepancy magnitude using correlation metrics (e.g., ISO/SAE J2749, MADYMO-based ratings).
Baselinecapability
07
Measurement phase gate review
verifying data integrity, repeatability, and reproducibility of simulation results.
Measurementverifying
08
Analyze phase overview
stratification, graphical analysis, and multi-vari studies for simulation discrepancies.
stratificationgraphical
09
Cause-and-effect analysis
Ishikawa diagrams, FMEA, and fault tree analysis applied to crash simulation workflows.
Cause-and-effectanalysis
10
Hypothesis testing for simulation correlation
statistical tests for comparing curve signals and injury criteria.
Hypothesissimulation
11
Sensitivity analysis and variance decomposition
identifying dominant model parameters via Sobol indices and ANOVA.
Sensitivityanalysis
12
Root cause verification
designed simulation experiments to confirm suspected causes (e.g., material model, contact, boundary conditions).
verificationdesigned
13
Common root cause categories in crash simulation
geometry idealization, mesh quality, material card errors, and solver settings.
categoriessimulation
14
Root cause investigation for intrusion and acceleration pulse discrepancies
case-based analysis.
investigationintrusion
15
Root cause investigation for occupant injury criteria discrepancies
dummy model, restraint system, and belt routing issues.
investigationoccupant
16
Improve phase
generating and prioritizing countermeasures for simulation correlation improvement.
generatingprioritizing
17
Model updating and calibration strategies
parameter identification, optimization, and validation against physical tests.
updatingcalibration
18
Implementing countermeasures
updating CAE best practices, solver settings, and material databases.
Implementingcountermeasures
19
Pilot validation of improvements
confirmation runs, cross-validation, and correlation metric re-assessment.
validationimprovements
20
Control phase
standardizing correlation workflows, documentation, and knowledge management.
standardizingcorrelation
21
Statistical process control for simulation correlation
control charts for key output metrics and drift detection.
Statisticalsimulation
22
Lessons learned and continuous improvement
integrating DMAIC findings into CAE quality systems.
continuousimprovement
23
Case study
DMAIC investigation of a frontal impact simulation discrepancy—from define to control.
DMAICinvestigation
24
Case study
side impact simulation correlation issue—root cause and improvement.
simulationcorrelation
25
Case study
pedestrian protection simulation mismatch—measurement and analysis phases.
pedestrianprotection
26
Practical workshop
building a project charter and measurement plan for a given simulation discrepancy.
workshopbuilding
27
Practical workshop
conducting root cause analysis using Ishikawa and hypothesis testing on sample data.
workshopconducting
28
Practical workshop
designing a DOE for model calibration and validating improvements.
workshopdesigning
29
Practical workshop
developing control plan and standard operating procedures for simulation correlation.
workshopdeveloping
30
Capstone project
end-to-end DMAIC investigation of a real-world crash simulation discrepancy, including report and presentation.
Capstoneend-to-end