The global auto parts manufacturing market reached approximately USD 701.57 billion in 2023.* We’ll look at Lean and Six Sigma applications from China, Croatia, Brazil, and Morocco and finish with a video of making VW auto parts.
Using Lean Six Sigma to Achieve Process Transformation in Auto Parts Industry: China
In a brief paper titled “A Study Based on Lean Six Sigma Auto Parts Production” authors Zhimin Qiu, Jie Zhang, and Jiunan Xu discuss the use of Lean Six Sigma to achieve process transformation in an auto parts company.
The study includes Auto Parts Company Warehouse Stock Materials Amount Distribution Chart
You can read the paper here.
Six Sigma Applied for Process Improvement in Auto Parts Production: Croatia
In a paper titled “Six Sigma process improvements in automotive parts production” authors M. Soković, D. Pavletić,and E. Krulčić discuss a Six Sigma project to identify and reduce production costs in an auto parts company.
The paper includes:
- DMAIC Methodology for Running Six Sigma Projects
- Pareto Chart of Total Expenses in Deburring Department
- Thought Process Map
- Casting Part with Positioning Points
- Box Plot Analysis
- Multi-Vari Analysis
- Measurement Systems Analysis
- Actual and Predicted Value of Ratio Volume/Cost
You can read the paper here.
Adoption of Lean and Quality Methods in Brazilian Auto Parts Companies: Brazil
In a paper titled “Adoption of lean and quality methods in auto parts companies” authors Lilian Carneiro Souza and Alessandra Rachid discuss the adoption of Lean and quality methods in Brazilian auto parts companies.
The authors surveyed 95 companies.
The paper includes:
- Sizes of Companies Under Investigation
- Adoption of Management Methods by Investigated Companies
- Methods that were Discontinued (% Relative to Total Adopted)
- Worker Involvement in Application of Methods
- Worker Involvement in Different Activities
- Production Areas and Worker Flexibility
- Frequencies of Cited Training Programs According to Type
You can read the paper here.
Lean Manufacturing in Automotive Metal Components Manufacturing: Morocco
In a case study titled “Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry” authors Hanane Rifqi and others discuss the results of applying Lean
manufacturing through the DMAIC concept in a company that produces automotive metal components.
After a discussion of Lean Manufacturing and DMAIC, the case study includes:
- Factory Plan
- Current Situation Map
- Comparison of Rate and Customer Takt Time
- Spaghetti Diagram
- Press Wastes
- New Press Configuration
- Old vs New Production Planning
- Water Spider Route
- New Workshop Configuration for Press
- A3 Thinking
- Total Costs and Savings of Solutions
- Conclusion:
- Turnaround Time Reduction
- WIP Reduction
- Increase in Storage Space
- Reduction in Forklift Load
- Increase in Safety Level
- Streamlined Workshop Flow
Copy and paste the following link into your browser to access the case study.
Manufacturing Volkswagen Auto Parts
See how Volkswagen auto parts are made at the VW Kassel Plant in this video from Cars Garage.
You can watch the video here.
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