Using the orthogonal arrays and the occupant analysis software based on the multi-body dynamics , two interactive design algorithms are proposed to improve the initial design of the occupant protection systems. Algorithm 1 sequentially moves the narrow design space within the upper and the lower design limit. Algorithm 2 sequentially reduces the relatively wide design space. Each design algorithm is composed of two levels . The first level is to improve the characteristics of the crash performance considering the noise factors. In order to obtain the robust design, the second level reduces the variations the noise factors. In order to obtain the robust design, the second level reduces the variations due to the tolerance of the design variable. To utilize the algorithm 1, HIC(Head Injury Criterion) , 3 msec criterion value of the chest acceleration and the femur load decreased by 27.4%, 10.4% and 55.8%, respectively. To utilizer the algorithm 2 , the results decreased by 38.0%, 10.5% and 3.0% , respectively.