Vehicle manufacturers worldwide are consistently looking for ways to implement new processes and systems to simplify their operations. This industry has come a long way from when it started being commercialized and vehicles started being mass-produced.
Currently, there is a wide variety of automated systems that help with factory production line productivity. However, recently using Six Sigma principles seems to be the new revolutionary trend aimed at overhauling this industry and improving operations. How is this happening? Here is how Six Sigma tools are revolutionizing the automobile sector.
Brainstorming cost reduction without compromising on quality
The main tenets of the Six Sigma tools are Define, Measure, Analyze, Improve and Control (DMAIC). They are taught by 6Sigma.us, which is headed by Peter Peterka, a veteran in applying Six Sigma principles with over 20 years of experience. These five tenets of Six Sigma guide the principles of this statistical analysis and quality checking framework. Thus, it is very useful when brainstorming how to reduce costs without compromising on quality.
Setting a baseline, which falls under the defining phase, can ascertain the current costs related to manufacturing automobile parts. Afterward, all the other principles can come to play when you implement them systematically to significantly reduce costs while maintaining quality product manufacturing.
Measurable process improvements
Some processes involved in the manufacturing and distribution of vehicles can be attributed to Key Performance Indicators that can be measured. These KPIs attributed to certain processes can help measure and collect statistical data that can later be analyzed using Six Sigma principles.
Subsequently, plant processes and procedures can be improved significantly and lead to high-quality vehicle parts manufactured using sustainable methods. Measuring KPIs like the overall time spent assembling or manufacturing a vehicle part can also promote productivity and streamline profit margins.
Minimizing defect-causing risks
From the conceptualization of the vehicle design right to the final assembly, there is some margin for error and miscalculations along the line. Some of these errors could be benign. However, others might even risk the profitability of the company. Before the design even goes to the production line, conducting a thorough statistical analysis can help minimize the risks caused by defects.
Using testing data, statistical analysts can recognize faults or defects that could potentially ruin the end product. In that sense, Six Sigma principles can prevent recalling vehicles with defects and thus saving hundreds of thousands if not millions of dollars for automobile companies.
Critical analysis of production line capacity
One very important aspect of automobile part manufacturing and vehicle assembling is the production line capacity. To meet the set performance objectives, a critical analysis needs to be conducted on the production line capacity. That can help ascertain whether the plant needs some improvements or if it is being underused in terms of its capacity.
Analyzing statistics related to the manufacturer guidelines regarding usage capacity can help decide on any adjustments to work shifts or improvements. A data-driven decision can help save money by wisely using human resources and equipment.
Benchmarking and improving safety on vehicles
Vehicle safety has become the prime concern of car part manufacturing and assembling. For almost all the changes and facelifts made on the latest vehicles, safety has to be carefully considered. For example, more OEM systems that aid drivers to avert car accidents have been outfitted to vehicles on the production line.
Six Sigma principles come into effect when benchmarking gestures and movements that could lead to accidents. For example, an OEM systems manufacturer of this kind had to gauge how much notice is needed to avoid a collision that a distracted driver could cause. Critical statistical analysis was required to make a definitive decision on when an alarm should be sounded to alert the driver of the potential accident.