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When designing a new subsystem for a new vehicle platform, technical requirements, performance targets and cost implications drive the decision process towards which concept to be adopted. If this platform is planned for worldwide introduction, local requirements and capabilities have to be put into the business equation. Among the possible design options for a Side Door Subsystem, including basically Inset doors and Limo doors with their variations, the best for the market is selected on: Commonality requirements through the platform family; Technical implications of each design concept; Technical excellence to produce parts with the required quality/cost in the local market; Costs and timing associated with each design concept; Benchmarking. This composition of factors drove the decision to adopt different design options for South America and Europe on the recently launched small car platform.

Very often, engineering problems involve several variables that have different physical behavior making theoretical modeling complex and difficult. In the present paper, 6-Sigma tools were used to develop an experimental model that describes the system. The issue in focus was the vibration observed at the top of rear door during normal opening operation, causing the impression of a fragile structure. The resulting experimental model was able to explain door opening vibration with only 15% of error. In addition, it was possible to choose the best combination and setting for each variable in order to achieve a product benchmarking value.