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Ford Team Uses Six Sigma to Reduce Costs While Improving Environmental Impact

Summary: Performance metrics signaled increases in basecoat paint consumption at Ford’s vehicle operations center in Saarlouis, Germany. A cross-functional Six Sigma team was chartered to solve the problem using a DMAIC approach. Using a variety of quality tools, the team identified root causes before developing and testing potential solutions. By reducing paint expenditures, the team achieved a $2 million annual savings. Ford entered this project in ASQ’s 2011 International Team Excellence Award competition where it earned finalist honors.

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