Case Study: Tenneco reduces steel tubing scrap by 50% with Minitab Statistical Software

Using Six Sigma to Reduce Scrap, Rework, and Costs at Tenneco

Tenneco, a global manufacturer of clean air and ride performance products, faced a challenge at its Litchfield, Michigan facility: reduce the scrap rate for 2.5-inch steel tubing used in exhaust systems by 50 percent. To support the effort, Tenneco used Minitab Statistical Software as part of a Six Sigma initiative focused on cutting scrap and rework.

With Minitab, Tenneco’s team followed DMAIC, mapped the process, analyzed defect data, and used hypothesis tests and ANOVA to pinpoint key drivers such as tooling, setup, and weld-zone temperature. The company implemented improved tooling controls, standardized setup conditions, and temperature parameters, and achieved a 50 percent reduction in scrap, along with better efficiency in internal and external customer departments and successful rollout of improvements to sister facilities.

Tenneco

Dan Wolfe

Lean Six Sigma Master Black Belt and Master Black Belt Manager