Key Points

• Lean Six Sigma helps manufacturers build more efficient, quality vehicles.
• Tools like DFSS, DMAIC, and FMEA can help to guarantee quality during every step of the manufacturing process.
• Lean Six Sigma is a proven, tested methodology, being used by some of the top names in the automotive industry.

Few industries require the same sort of precision, efficiency, and need for continuous improvement as automotive manufacturing. Building vehicles at any sort of scale is a massive undertaking involving thousands of parts, a network of suppliers, and assembly lines running around the clock. The global market isn’t exactly forgiving when it comes to cars either, as consumers demand flawless quality, government regulatory bodies have strict compliance requirements, and margins are razor-thin.

The automotive industry has been accustomed to the use of methodologies like Lean and Six Sigma for decades at this point. To stay competitive, you need to leverage every advantage you have, and Lean Six Sigma provides a comprehensive, powerful framework for driving quality gains, reducing waste, and delivering cars that meet and exceed customer expectations. Today, we’re looking at why any automotive manufacturer should make use of Lean Six Sigma.

The Foundation

Lean Six Sigma is often mentioned as a monolithic methodology when looking at any sort of documentation online. Lean and Six Sigma have completely different points of origin, despite sharing similar aims. Further, they address different aspects of the manufacturing process, making for complementary approaches.

Lean focuses primarily on the elimination of waste. Activities or resources that don’t add value to a final product are a fixture when looking at how to drive efficiency in Lean. Lean itself identifies 8 wastes, like overproduction, excess inventory, waiting times, unnecessary motion, and defects, among others. The idea behind the methodology is to create a flow, or smooth, efficient process that delivers value while maximizing resource utilization.

Six Sigma, on the other hand, is about driving consistency through reducing variation and defects. To this end, Six Sigma utilizes data-driven analysis, often coupled with statistical quality control, to aim for near perfection. Six Sigma isn’t just a methodology. It is also a measure of quality, with a Sigma level of 6 denoting 3.4 defects per million opportunities. When combining forces, you have a system that establishes process flow while guaranteeing product quality, making for an invaluable combination in automotive manufacturing.

Building Quality

Automotive manufacturing isn’t just about building cars. You’re creating systems that ensure quality from design to final delivery. Lean Six Sigma principles are embedded in every step of the lifecycle as well.

Design and development are handled by tools like Design for Six Sigma (DFSS), which puts quality in mind from the earliest stages. Design cues are taken from the Voice of the Customer, which ensures customer needs inform design decisions. Statistical models can help predict performance before a prototype is built.

Handling the supply chain for any automotive manufacturing is a rather tall order. You’re dealing with a complex, vast system that needs a deft hand to navigate ably. Lean Six Sigma tools like Failure Mode and Effects Analysis and Supplier Process Capability Analysis mean you’re guaranteeing quality standards from your suppliers and addressing issues before delays or defects happen.

Finally, production and assembly are going to make use of techniques like 5S, Kaizen, and Value Stream Mapping. These help to streamline workflows, visualize bottlenecks, and eliminate non-value-added steps that crop up in any process. Later down the line, you can leverage DMAIC to pinpoint causes of variation and drive continuous improvement.

Real-World Impacts: Lean Six Sigma in Action

Lean and Six Sigma have had definitive real-world impacts on some automotive manufacturers. When some of the biggest names are making use of it, you know you’re in good company. Toyota might not leverage some of the Six Sigma tools we’ve mentioned, but the Toyota Production System is the direct inspiration for Lean. TPS continues to set industry benchmarks when it comes to eliminating waste, empowering workers, and maintaining flexible assembly lines.

Ford integrated Six Sigma into its global operations in the 2000s and saw substantial savings when looking at warranty costs. Quality went up, defects went down, and Ford was able to see billions in savings just through a fundamental shift in the corporate culture.

General Motors has also been a big proponent of Lean Six Sigma, which can be seen at some of its assembly plants. The Lansing Delta Township campus has seen targeted Lean Six Sigma projects, which have reduced equipment downtime by 40%, resulting in increased production capacity and fewer quality issues.

Lean Six Sigma is more than a theoretical framework. It is a proven strategy for achieving measurable success, along with seeing substantial gains in performance and quality.

Reducing Defects, Increasing Safety

Safety and reliability are top concerns for any customer looking to buy a car. In automotive manufacturing, even a minor defect can result in fatalities. As such, you need to make sure you’re delivering quality. Tools from Six Sigma, like statistical process control and root-cause analysis, help to identify and eliminate potential failure points before they reach customers.

Further, you can apply Six Sigma principles to tools like the aforementioned Failure Mode and Effects Analysis to prioritize risk based on severity, occurrence, and detectability. Your most critical issues are getting addressed first, and you can take a look at lesser issues if your time and budget allow.

Making use of these tools results in safer, more reliable vehicles. It also has the added benefit of fewer recalls, warranty claims, and damaging reputational hits your brand might receive.

Culture Changes: Beyond Tools and Buzzwords

Implementing Lean Six Sigma isn’t just about using the latest and greatest tools and technologies. It requires a complete cultural shift to sustain improvements and build toward a better future. Many in the automotive industry already understand that continuous improvement requires buy-in from everyone, all the way down to the plant floor and into the CEO’s office.

Employee empowerment is a key part of any implementation. Workers should be trained to recognize inefficiencies and suggest improvements. This isn’t just good for business, but it also builds a more skilled, self-reliant workforce. Innovation starts from unlikely places, and your front-line employees might just have what is needed.

Continuous improvement simply needs to become part of your company, down to the molecular level. Without it, any sort of initiatives and gains aren’t lasting. Eventually, quality will plateau, and you’ll be left wondering what you could do to change things. Instead, you could simply commit and see those improvements compound and create a stronger organization.

What Comes Next

The automotive industry is rapidly evolving. Electric vehicles, autonomous driving platforms, and digital supply chains are transforming how companies are building cars. Yet, despite these massive changes, methodologies like Lean Six Sigma will continue to remain relevant. In fact, as cars continue getting more complex, the need for precise, practical, and quality-focused processes is going to be more important than ever before.

Forward-thinking manufacturers are already integrating Lean Six Sigma with advanced technologies like artificial intelligence, Internet of Things, and predictive analytics. Embracing new technologies promises greater gains, and the ability to conduct real-time process monitoring, predictive maintenance, and AI-driven defect detection is going to still a commitment to providing the best possible cars to your customers.

Other Useful Tools and Techniques

Ready to keep going? You might want to take a look at how you can utilize Value Stream Mapping for service operations. VSM is a fantastic tool for visualizing pain points and bottlenecks, which can be readily seen in any sort of service operations.

You might also want to take a closer look at how to leverage Lean Six Sigma to streamline your cybersecurity operations. Cybersecurity is one area of any business that is in dire need of streamlining, and learning how to quantify and reduce waste and defects can lead to a stronger business posture on the whole.

Conclusion

With how competitive and cutthroat the automotive industry is, few manufacturers can just leave things to chance. Leveraging Lean Six Sigma gives a complete system for building better vehicles while maintaining efficiency, reliability, and safety. By making continuous improvement the central focus of your organization, you aren’t just building cars that meet expectations, but redefine them.