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In the automotive industry it is perceived a continuous time decreasing for new vehicles models launches, as an increasing of customer expectations that the new launches will not present problems due to lack of manufacturing process or due to projects not properly tested. Project or process adjustments during vehicle serial production are not acceptable anymore due to current market competition. In this way the Design of Experiments (DOE) came up to help the industry in set the optimum adjustments for products and process parameters, even in the beginning stages of product development. This paper presents an application of DOE as a support tool for the development of a Drive Shaft (DS) retention system. The steps of a generic model for industrial experimentation were followed in order to develop this case study. This generic model covers all the steps of planning and conducting of an experiment.

This study registers a finite element analysis of a seal boot used in constant velocity driveshafts. By this analysis the structure's behavior is studied in its work life before construction of the actual prototype. Prototype development time can be saved in the design phase since the part can be improved by this theoretical prediction tool. Failure points are predicted by the analysis saving resources such as developing production tools, making prototypes and testing them to finally detect the items that have to be improved. Analysis are made regarding an existing seal rubber boot. Then the results of general part are examined and contrasted with laboratory test reports of the real part.