Applying DMADV on the industrialization of updated components in the automotive sector: a case study

Abstract Lean in project management is an essential methodology for success in the automotive industry. This industry, usually, focuses its strategy in continuous improvement, governed by the Japanese model, the Toyota Production System (TPS). The challenge of this work was the industrialization of a component for an automotive OEM customer, respecting the quality and price ratio. This project was carried out focused on the use of the DMADV methodology in the management of an industrialization project regarding an updated part for the automotive industry. Thus, the process was mapped in detail, using five main steps: Define, Measure, Analyse, Design and Verify. The product corresponds to a piping system for air conditioning of motor vehicles. Its production in series needed a strong improvement in order to fulfill the demanding program required by the market and comply with the quality - price ratio. It was concluded that the project allowed the development of prototypes from the embryonic stage (2D) to the final design. During the industrialization project, finished prototypes were shipped to the customer following the milestones required by the customer, without any nonconformity in the final product. At a later stage, the transition from industrialization to serial production was successfully completed.