Automotive & Assembly

We help businesses define long-term strategies, capture market opportunities, and build a strong, sustainable competitive edge for lasting success worldwide.

AUTOMOTIVE PRACTICE

Precision at Every Stage

Arrow Ways embeds engineering expertise directly into automotive programs — eliminating bottlenecks, applying Six Sigma discipline, and advancing electrical systems that power next-generation vehicles.

3.4 Defects Per Million Six Sigma Target

40% Avg. Cycle-time Reduction Bottleneck Engagements

EV Battery, Bms & Power Electronics Focus

OEM Tier 1/2 Supplier & OEM Program Support

PROCESS OPTIMIZATION

Bottleneck Elimination

Production delays compound. A single constraint can throttle an entire program. Arrow Ways maps your value stream, isolates the binding constraint, and engineers a durable fix — not a workaround.

04 Steps Process

Value Stream Mapping

We document every step — stamping, welding, assembly, test — and surface where throughput collapses. No assumptions, only data from the shop floor.

Theory of Constraints

Using Goldratt's TOC framework, we identify the one constraint governing the system and subordinate all other decisions to exploiting it before investing in capacity elsewhere.

Root Cause Analysis

Fishbone diagrams, 5 Whys, and fault-tree analysis drive every investigation. We reach the mechanical, electrical, or process-design cause — never just the symptom.

Sustained Flow Design

After resolution, we redesign the surrounding process — line balancing, takt-time alignment, buffer strategy — so the constraint does not simply migrate downstream.

QUALITY SYSTEMS

Six Sigma Discipline

Arrow Ways deploys Black Belt-level methodology across automotive programs — from stamped body panels to battery cell integration — driving defect rates toward statistical zero.

D	DEFINE Scope the problem in business terms. Establish CTQ characteristics, project charter, and measurable goal aligned to program timing and cost targets.

M	MEASURE Collect baseline process data. Establish MSA validity before trusting any number. Capability indices (Cp, Cpk) are calculated against specification.

A	ANALYZE Statistical tools — regression, ANOVA, Pareto — isolate the vital few X’s driving variation. Graphical analysis makes the case visible to every stakeholder.

I	IMPROVE DOE (Design of Experiments) validates that proposed changes move the needle. Improvements are piloted, measured, and confirmed before full-scale rollout.

C	CONTROL Control plans, SPC charts, and updated work instructions lock in the gain. Ongoing monitoring catches drift before it becomes a warranty event.

Key Quality Benchmarks

Process Sigma Level Target Defect Prevention Vs. Detection APQP / PPAP Alignment

≥ 5σ

233 defects per million — a rigorous interim milestone on the path to full Six Sigma performance.

10:1

The cost ratio of preventing a defect at design stage versus catching it at customer delivery.

Full
Every engagement is structured around APQP and PPAP milestones, keeping supplier and OEM timelines synchronized.

ELECTRICAL SYSTEMS

Power, Control & Integration

As vehicles become software-defined platforms, electrical engineering is no longer a subsystem — it is the system. Arrow Ways staffs and leads electrical work at component, subsystem, and vehicle level.

Battery Management Systems

Cell balancing algorithms, state-of-charge estimation, thermal management control, and pack-level protection logic — engineered for the safety and cycle-life demands of automotive duty cycles.

Power
Electronics

Inverter and converter design, thermal derating analysis, EMC compliance, and gate-drive optimization for traction and auxiliary systems across 48V, 400V, and 800V architectures.

Signal Integrity & Harness

CAN, LIN, Ethernet, and FlexRay topology design; wiring harness routing and weight optimization; connector selection and DFMEA — from early architecture through production validation.

ECU Integration & Calibration

Software-in-the-loop and hardware-in-the-loop testing, calibration data management, and integration validation across multi-ECU vehicle architectures using AUTOSAR-aligned frameworks.

Functional Safety — ISO 26262

ASIL decomposition, HARA, safety concept development, and verification evidence — supporting ASIL A through D classification across EV and hybrid platforms.

Digital Twin & Simulation

Model-based design using MATLAB/Simulink, virtual validation of control strategies, and HIL bench setup — compressing test cycles and catching failures before physical hardware exists.

Still Have Questions? Let’s Talk Today!

Start the conversation and discover how we can help.

ENGAGE ARROW WAYS

Your Program Our Engineers

Whether you need to staff a program gap, lead a quality improvement initiative, or bring electrical engineering depth to a vehicle integration challenge — Arrow Ways deploys the right expertise, fast.