This paper describes a study that was conducted to determine sensitivity of several design factors for reducing injury values of occupants upon side impact using Taguchi method. The full mid-sized vehicle finite element model is used for the analysis under two different side impact standards - SINCAP and ECE-R 95. The design factors that may have major effect on side impacts were selected and L₈ orthogonal array was set up for analysis.

Analysis results show that strengthening the passenger compartment improve occupant protection, especially adding a pusher foam is significantly lowering the injury values in SINCAP. No single factor has major effects on rib deflection which is considered as critical occupant injury criterion in ECE-R 95.

Taguchi method was found to be a useful tool, although its usage may be limited in crash analysis, for predicting the effect of various design factors on structure