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Improving assembly processes through optimized development and Six Sigma in the automotive industry

Initial situation

  • A European car manufacturer needed support in ramping up newly installed assembly lines to ensure rapid stabilization of production
  • The market environment was highly competitive and characterized by strict quality requirements and tight delivery deadlines
  • The newly developed product family posed technological challenges due to the selected manufacturing processes, resulting in high scrap costs and additional rework
  • To stabilize production, significant increases in quality, performance, and availability needed to be achieved

Achievements

0 %
Rework reduced
1,8 Mio. €
Savings realized over the duration of the project​
0 %
Scrap costs reduced​

Our approach

  • Provide methodological support to sprint teams in the following areas
    • Conduct a holistic analysis of the current situation using Six Sigma methods to identify the root causes of scrap (individual parts, measuring systems, machines, process steps)
    • Support the development of a digital twin for the entire production process to quantify the greatest benefit contribution
    • Derive and implement technical solutions
    • Introduce measures to prevent errors (Poka Yoke)
  • Closely involve employees to ensure acceptance of the measures​

Further cases

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Increased efficiency in quality inspections through AI-supported image recognition in the automotive industry

All cases

Discover more references.