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Gauge R&R (GR&R), as defined through Measurement Systems Analysis (MSA), has long been an accepted technique to validate the consistency of a measurement system (gauge), whether it is in the lab or used in end of line (EOL) applications. The analysis process, defined by Automotive Industry Action Group (AIAG), is typically applied to an attribute that is inherently stable and repeatable, and a measurement process that is just as robust and single valued, e.g. measuring the diameter of a part with a caliper. In the world of NVH, the parts are stable and the measurement system is robust; however, the measured results are not as repeatable as desired due to the nature of the system. In the NVH realm, the results are typically multi-value, e.g. an order slice vs. RPM. How is a traditionally single value process applied to a multi-value result, pick 1 point? An additional challenge to the traditional MSA analysis is that it requires a linear amplitude relationship of the measured result.

This paper outlines the use of using an Analytical Fault Tree model to predict the reliability of a brushed DC motor using control electronics and software for an automatic open and close control. The use of predictive reliability used in the up front design shows where the emphasis on design improvement needs to be focused. This analytical tool also provides the occurrence numbers needed when we start working on the DFMEA. This type of analysis has been validated by actual test data supporting the prediction with virtually no failures of the system at 1 life in service.

There are many tools available in the philosophy of six sigma and all of them share one thing in common. A structured approach to problem solving. A structured approach will have application no matter what the nature of the problem or where in the organization it might fall. By following a discipline an effective solution to a problem can be found efficiently and at minimal cost with long lasting effects. This paper uses a specific problem of variation in design that was discovered in a brand new application of an existing technology. The form of problem solving is known by many names such as TOPs, Brainstorming, PDCA, and other acronyms but they are all designed to do the same thing, organize the thinking process and structure the approach to determine the final solution without guessing. In this instance the PDCA (Plan, Do, Check, Act) approach was applied to determine the root cause of the variation of a hydraulic valve.