Reducing the Scrap Generation by Continuous Improvement: A Case Study in the Manufacture of Components for the Automotive Industry

  • J. Pereira
  • F. J. G. Silva
  • J. C. SáEmail author
  • J. A. Bastos
Conference paper
Part of the Lecture Notes in Networks and Systems book series (LNNS, volume 122)


The automotive industry is one of the most demanding sectors of the global market. The response capacity and flexibility of companies represent a key factor for their success. Applying Six Sigma, it was carried out an improvement project aiming at reducing the quantity of scrap on the most critical sector of a automotive components’ manufacturer achieving a better comprehension of the flows, process characteristics and different variables associated to the scrap generation, identifying the equipment responsible for that scrap and its type. Brain- storming sessions were performed, as well as the application of 5 Why’s and 5W2H techniques in order to fulfill the Ishikawa diagrams aiming at understanding possible root-causes for the scrap generation. A definition of the improvement actions has been developed. A reduction of 15% was achieve just in the machine identified as the main generator of scrap in these processes.


DMAIC Continuous improvement Six sigma OEE Automotive industry 


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Copyright information

© Springer Nature Switzerland AG 2020

Authors and Affiliations

  • J. Pereira
    • 1
  • F. J. G. Silva
    • 1
  • J. C. Sá
    • 1
    • 2
    Email author
  • J. A. Bastos
    • 1
  1. 1.ISEP—School of EngineeringPolytechnic of PortoPortoPortugal
  2. 2.IPVC—School of Business SciencesPolytechnic Institute of Viana Do CasteloValençaPortugal

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