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Currently the Automotive industry demands highly competitive product to survive in the global tough competition. Even if there is a slight reduction in product cost and time has a high significant impact on business. Engineers are under tremendous pressure to develop competitive and give better product concern resolution at the earliest. To arrest the failure of this thermostat vent, an innovative approach was used to relocate de-aeration restrictor on the hose to the thermostat root. Thus, resolving the product concern by increasing the strength of the vent at root and providing good business impact on cost savings. Physical testing has provided an effective way to smoothen product development for concern resolution. This Paper highlights approach on an attempt to field failure simulation with existing and modified design with lab test results.

All Automotive companies conduct various performance and Endurance tests on automotive bodies, doors by using Pneumatic Actuators. These Actuators can only give linear or rotary motion. Therefore these can neither simulate the complex motion of Human arm nor can they simulate the Force and pressure induced by the Human palm or Human back on the body domain parts. Each test need to have different test setup. This paper discusses how a system of industrial Robot coupled with intelligent Gripper with sensors and feedback signal to robot can be used to simulate the effect of Human touch during testing.