World leading automotive manufacturer wanted to enhance product development and process engineering capabilities

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The company

The company is one of the world’s largest automobile manufacturers and sells family automobiles, commercial vehicles and luxury cars. Over a hundred years ago the company introduced methods for large-scale manufacturing of cars and large-scale management of an industrial workforce using elaborately engineered manufacturing sequences typified by moving assembly lines, which were copied by other manufacturers.

Their needs

The group wanted to build on its huge past successes by being at the vanguard of creating lean six sigma capability initially in its production engineering and product development groups as a way of increasing market share and reducing new product development lead time.

How we helped

We assisted a large US consultancy by providing teaching and coaching assistance for a wide array of black belts and project champions in German, French and UK factories and offices. We also coached numerous senior managers in variation reduction techniques and helped them ensure projects were scoped and mentored appropriately.


Numerous projects were completed, providing a significant return on investment including:

      • Reducing coolant failure

      • Reducing final drive noise

      • Reducing 1st & 2nd gear whine

      • Reducing ring gear deformation

      • Improving bill of material integrity

      • Reducing steering column squeaks

      • Hatchback tailgate slam effort optimisation

      • Reducing transit van ground battery cable failures

      • Reducing incidence of cavities in tailgate sealant

      • Reducing development vehicle documentation delivery delays

      • Reducing toe alignment variation

      • Reducing ride height variation

      • Reducing speedometer reading gauge variation

      • Reducing fuel gauge errors

      • Reducing rework on production vehicles for motor shows


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