How Six Sigma Drives Quality and Efficiency in EMS

In electronics manufacturing, even small inconsistencies can lead to delays, rework, or product recalls. That’s why more manufacturing partners are turning to Six Sigma to protect quality at every stage.

For companies like IMS Electronics Manufacturing, integrating Six Sigma principles isn’t just a box to check. It’s a clear signal of our commitment to meeting the highest standards in manufacturing.

Six Sigma in electronics manufacturing plays a vital role in reducing defects and improving process control across complex, high-volume builds. At IMS Electronics Manufacturing, Six Sigma is more than a quality standard—it’s part of how we deliver consistent, scalable results. By combining DMAIC, Lean, 5S, and automation, IMS builds reliability into every stage of production.

Six Sigma is more than a buzzword. It’s a globally recognized framework for improving quality in manufacturing environments where precision matters most. Originally developed by Bill Smith at Motorola and later adopted by giants like GE and Honeywell, Six Sigma uses a data-driven, five-step process (DMAIC: Define, Measure, Analyze, Improve, Control) to systematically identify and eliminate defects.

In electronics manufacturing, where tolerances are tight and even minor inconsistencies can lead to failure, Six Sigma helps teams dial in their processes with incredible accuracy. Industries like aerospace, automotive, and medical devices often require Six Sigma compliance from their suppliers, meaning companies that adopt this methodology are better positioned to serve high-standard customers and meet critical regulatory benchmarks.

At the heart of Six Sigma is the DMAIC cycle: a five-phase method that helps teams reduce variation and solve process issues.

1️⃣ Define
Identify the issue and its impact.
Example: High rates of cold solder joints during PCB assembly.

2️⃣ Measure
Collect data to understand scope and frequency.
This might include defect rates by machine, shift, or solder material.

3️⃣ Analyze
Pinpoint the root cause using tools like fishbone diagrams or Pareto charts.
In this case, inconsistent preheat temperatures may be to blame.

4️⃣ Improve
Test and implement a solution.
IMS might adjust reflow oven settings or update prep procedures.

5️⃣ Control
Put monitoring systems in place to sustain the fix.
This could involve thermal profiling or new inspection checkpoints.

DMAIC gives manufacturers like IMS a repeatable, evidence-based approach to quality improvement—one that scales with production volume and complexity.

Build with precision. Scale with confidence.
Learn more about our quality promise →

In electronics manufacturing, quality issues are expensive. A misaligned component, faulty solder joint, or micro-crack in a PCB can cause failures that aren’t always caught during testing. The fallout? Product recalls, warranty claims, missed deadlines, and reputational damage.

Six Sigma addresses the problem at its source.

By identifying root causes and eliminating variation, Six Sigma helps manufacturers:

• Reduce rework and scrap.
• Catch potential failures early.
• Build consistent, reliable products.

This approach strengthens every part of the production process, from first build to final inspection.

Modern electronics manufacturing moves fast. Products are more complex, lead times are tighter, and expectations for precision are at an all-time high. To stay competitive, manufacturers need systems that support both accuracy and efficiency—without forcing a trade-off.

Six Sigma delivers this by embedding quality into the process itself.

For example, IMS uses process mapping and root cause analysis tools (two core Six Sigma practices) to identify where variation is likely to occur. This might involve analyzing solder joint defects under specific humidity conditions or measuring assembly line timing to catch micro-delays that impact the pace of production.

Once a pattern is identified, it’s corrected before it becomes a recurring issue.

This proactive approach minimizes downtime, reduces rework, and keeps production moving efficiently, even as volume increases. Combined with Lean, 5S practices, and automation, Six Sigma helps IMS deliver faster without compromising precision.

Our team is actively implementing Lean and Six Sigma principles across departments, combining data-driven decision-making with hands-on process improvements. From quote to final build, quality is built in—not added on at the end.

Engineers and production staff are trained to identify process variation, reduce waste, and flag improvement opportunities in real time. Tools like root cause analysis, control charts, and standardized work instructions are already helping reduce rework and improve consistency across both electronics assembly and metal fabrication.

This commitment reflects a broader promise: to deliver Solid Service, Solid Quality, and a Solid Product—on every build, at every scale.

Take a closer look inside our facility.

See how our team applies Lean and Six Sigma principles every day: from electronics assembly to final inspection.

Reach out to IMS and discover how our team applies Lean and Six Sigma in electronics manufacturing to build lasting solutions and stronger partnerships. Contact our team today!