Substantiation of a synergetic quality management model for new energy vehicles within the TQM, LEAN, and SIX SIGMA paradigms

Abstract

The article provides a comprehensive theoretical and applied substantiation of a synergetic quality management model for new energy vehicles (NEVs) in the context of rapid technological transformation and intensifying global competition. A paradigm shift is substantiated, moving from traditional reactive end-of-process inspection to a proactive whole-life-cycle management model based on the "Quality by Design" concept. It is proven that in conditions of high technological complexity of intelligent electric transport systems, isolated inspection methods lose their effectiveness, giving way to an integrated "design-manufacturing-service" system. The scientific novelty of the research lies in the conceptualization of an integrated toolkit that combines the philosophy of Total Quality Management (TQM), Lean Production tools, and Six Sigma precision. Two strategic stages of transformation are detailed: at the development stage: the implementation of structured processes (IPD) and preventive modeling tools (DFMEA, CAE), which ensure the elimination of up to 70% of potential defects before the start of mass production. In the manufacturing cycle: a transition to precision management through error-proofing systems, automated intelligent inspection, and end-to-end component traceability based on RFID/QR technologies. Particular attention is paid to the institutional and cultural determinants of the management system's stability. The role of cross-functional collaboration and management leadership is substantiated as a "soft" infrastructure that ensures the removal of information barriers and the formation of a "quality-first" culture. Based on a comparative analysis of traditional and innovative management models, it is proven that digital transformation and the use of Big Data are the only viable ways to achieve target reliability indicators in mass production scales.

The research results form a stable contour of municipal and industrial vitality for the industry, offering enterprises mechanisms for transitioning from a "scale expansion" strategy to a "high-tech competitiveness" strategy in the global market.