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The article presents an innovative approach to the implementation of a robust design optimization solution in an automobiles assembly process. The approach of the entire project is specific to the 6 Sigma optimization process, by applying the DMAIC cycle integrated in a robust engineering approach for rendering lean the final product assembly process. According to the improvement cycle, the aspects specific for such a process are presented sequentially starting with the “Define” phase for presenting the encountered problem and continuing with the presentation of the scope of the project and its objectives. The “Improvement” cycle phase is applied by the analysis of the monitored 6 Sigma metrics (defined during the previous “Measure” phase and the cause and effect analysis, done during a brainstorming meeting developed during the “Analyze” phase). There follows a proposal for the innovative robust solution by which the assembly process is optimized.

Using a prototype of terrain car as example, a process of flow simulation around a vehicle with rotating wheels is described by using a professional CFD (Computational Fluid Dynamics) software. The influence of the wheels motion on main aerodynamic characteristic of the car, drag, is studied in two ways, commonly used in wind tunnels [10], respectively with the moving wall approach and with the aid of the rollers for the wheels rotation. The conclusions are demonstrated by the results using the relative drag increment and by the computergraphics visualizations. There are also presented some considerations concerning the importance of the rotating wheels in aerodynamics of the road vehicle and the opportunity to simulate it in a virtual environment. The present contribution is a companion paper by Huminic & Chiru (2004).