The key players in the marine outboard engines market are Yamaha Motor Co. Ltd., Brunswick Corporation (Mercury Marine), Suzuki Motor Corporation, Honda Motor Co. Inc., Bombardier Recreational Products Inc., Tohatsu Corporation, AB Volvo, Suzhou Parsun Power Machine Co., Ltd., and Hidea Power Machinery Co., Ltd*.  Lean and Six Sigma are used in the manufacture of outboard engines and motorboats. We’ll look at applications from Thailand and the USA and finish with a video of how an outboard engine is made.

*Source: “Worldwide Marine Outboard Engines Industry to 2025 - Featuring Yamaha Motor, Brunswick & Suzuki Motor Among Others”


Lean and Lean Six Sigma in an Outboard Engine Manufacturing Plant: Thailand


In a case study titled “A comparison of process improvement between Lean and Lean-Six Sigma approach in outboard plant” authors Kunut Suksamarnovng and Jeerapat Ngaoprasertwong discuss and compare the use of Lean and Lean Six Sigma in an outboard engine manufacturing plant.

The authors list the results for before, Lean, and Lean Six Sigma approaches and  key performance indicator results  for both.

You can read the case study here.


Using Lean Manufacturing and DMAIC to Improve Materials Management in Outboard Engine Manufacturing: USA-Wisconsin


In a master’s thesis titled “Standardized Work Instruction” author Olivia Ruggles discusses the use of Lean Manufacturing and DMAIC to improve materials management in an outboard engine plant.

Standard work instructions provided a base for which adjustments, re-staffing, training, discipline and Lean activities would begin and documentation for positions and processes.

The thesis includes:

  • Forklift Driver Process Flow
  • Cause and Effect Diagram for Materials Function
  • Load Chart for Materials Operators
  • Current State Process Flow for Materials Movement
  • Operator Utilization Chart
  • Future State Process Flor for Materials Movement

You can access the thesis here.


5S Lean Manufacturing at Scout Boats: USA-South Carolina


In this video from TeamScoutBoats, Alan Lang Director of Marketing interviews Marty John, Director of New Product Development as they discuss Scout Boats use of 5S and Lean Manufacturing.

You can view the video here.


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Lean Six Sigma at Mercury Marine

In a short article titled “Lean, mean machine” Mercury Marine gives an overview of its use of Lean Six Sigma.

You can access the article here.


Making an Outboard Engine at Selva Marine

A video from The Boat Show covers the manufacture of outboard engines at Selva Marine, an Italian manufacturer. English captions translate from the Italian.


You can watch the video here.



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