Enhancing Scrap Reduction in Electric Motor Manufacturing for the Automotive Industry: A Case Study Using the PDCA (Plan–Do–Check–Act) Approach

Abstract

Featured Application: The PDCA (Plan–Do–Check–Act) cycle, coupled with supplementary quality tools like 5W + 2H (Who, What, When, Where, Why, How, How much), three-legged five-why analysis, control charts, and capability analysis, serves as a potent strategy in the automotive sector for scrap reduction. The automotive industry is increasingly focused on waste management, elimination, and reduction to achieve sustainability and cost reduction. This focus drives the industry towards resource-efficient operations that minimize environmental impact while exceeding customer expectations. Meeting these demands necessitates the adoption of more efficient production methodologies, such as the PDCA cycle. This work presents a case study that illustrates the application of the PDCA methodology to minimize scrap generation due to process variability in a multinational company that manufactures electric motors for the automotive industry. The aim was to demonstrate how the PDCA methodology can improve quality standards by minimizing scrap generated during the manufacture of electrical armatures. Notably, the organization in this case study set a waste target of 0.7%, which was significantly exceeded. Finally, the implementation of this methodology can deliver significant economic benefits, with a total annual cost reduction of approximately USD 135,000.