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Lean Six Sigma is an approach that is gaining momentum both in manufacturing and service industries. Design for Lean Six Sigma (DFLSS) is an outgrowth of the DFSS and Lean Six Sigma approaches. The essence of DFLSS is to ensure design quality and predictability during the early design phases and the approach employs a structured integrated product development methodology and a comprehensive set of robust tools to drive product quality, innovation, faster time to market, and lower product costs. When it comes to automotive Product Development, applying lean principles and DFSS together becomes more of a challenge within the existing PD system. While the benefits of DFLSS present an attractive proposition in a fiercely competitive market it brings its own challenges as to how to deploy it for maximum benefits. This paper examines the challenges, potential and opportunities for DFLSS in the automotive industry and presents a vision for integrating it in to the Product Development System.

This paper describes how DFSS tools provided the impetus in designing transfer gear for NVH performance and also discusses the design complexity and steps involved, tools used and the results obtained, within the DFSS framework. This paper describes gear noise reduction at source by reducing excitations at the transfer gear mesh with the given gear manufacturing variability. Gear Design for audible noise reduction is complex since the responses involved are continuous over a wide range of frequency and operating conditions. The objective here was to ensure that a future design meets the NVH targets cascaded to the component, in this case, transfer gears. The team used a Box Benkhen design to conduct hardware experimentation and subsequently to develop hundreds of transfer functions at different frequencies and operating conditions.