Integration of Lean and Six Sigma approaches to software development in improving quality processes of dry transformers

Purpose This article aimed to use Lean Manufacturing and Six Sigma approaches in the development of software to improve the quality process of the dry-type transformer industry by developing an automated validation system implemented through an object-oriented software architecture. Design/methodology/approach This study was based on an action research case conducted at a transformer and electric motor manufacturing company in Santa Catarina, Brazil. Software was developed to reduce failures related to coil dimensions, optimizing the data review process, previously performed manually. The solution was integrated with the company's enterprise resource planning (ERP) and engineering project management. Some development standards adopted were Model-View-ViewModel and Composite for data structuring and validation, in addition to Lean and Six Sigma approaches. Findings During the first six months of application, a potential cost reduction of around US$2000 was identified, eliminating approximately 2.33% of the total nonconformities recorded in the period and 2.26% of the costs related to these failures. Problems such as incorrect turns, diameters outside the specified limits and incompatible materials were avoided, promoting greater process reliability. The application of Lean and Six Sigma ensured a structured approach to identify and eliminate process failures, promoting gains in efficiency and quality. Costs associated with design errors and working hours were also reduced. Research limitations/implications Although the results were obtained only with a case applied in a large company and in the specific context of transformer manufacturing, there are opportunities to replicate the integration of Lean and Six Sigma in software development in other industrial sectors. Another limitation is the restriction on the use of the company's internal software in engineering project management, called GIS (Global Integration System). Practical implications The study contributes by showing how Lean and Six Sigma can be embedded into engineering software as a preventive quality mechanism, supporting defect prevention, specification compliance and transferable learning for other engineering-intensive organizations. Furthermore, the practical application reinforced the importance of working with multidisciplinary teams. Originality/value This study demonstrates how Lean Six Sigma principles can be translated from project-based improvement practices into a software-based preventive quality logic for engineering design. Its originality lies in integrating DMAIC (Define, Measure, Analyze, Improve and Control), poka-yoke and automated validation rules within an industrial engineering system and deriving a transferable implementation framework for organizations seeking to shift quality assurance upstream, before design errors reach production.