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It is well known that a robust design approach can be effective to improve safety performance on occupant protection in crash simulation. In this work, an automatic analysis system for frontal crash is developed. As the first step, sensitivity analysis is conducted by using both DOE (Design Of Experiment) and MCS (Monte Carlo Simulation) method to reduce the numbers of design variables and random variables. As a result of this work, a new design is obtained by using DFSS (Design For Six Sigma) method. Finally, the proposed robust design approach is confirmed by comparing experiments with simulated results.

It is well known that the variation of analysis parameters is a significant concern for the crash simulation of safety performance on occupant protection using FEM. In this work, an approach of DFSS (Design For Six Sigma) using approximation model is proposed to take account the variation on material and dummy position into the robust design optimization in the detail design stage of crash performance. As a result of this work, the mean value and deviation of the injury indices such as chest deflection and pelvis force are reduced and the sigma level of objective index is increased.