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This study has shown how the implementation of the DMAIC cycle (Define, Measure, Analyze, Improve, Control) in an automotive component industry can lead to a very significant reduction in material waste and, consequently, a reduction in the number of workers on certain assembly lines. Improvement actions were defined and implemented once the factors capable of eliminating and\/or reducing cable trimming on the assembly lines had been identified. With the actions implemented, about the case study used for validation, an annual gain of approximately \u20ac89,289 has been achieved and a gain of \u20ac288,343 will be achieved by approximately 2026, after the elimination of trimming on five assembly lines and the reduction of trimming on eight assembly lines.<\/jats:p>","DOI":"10.1007\/s00170-025-15367-4","type":"journal-article","created":{"date-parts":[[2025,3,18]],"date-time":"2025-03-18T05:03:34Z","timestamp":1742274214000},"page":"4143-4167","update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":1,"title":["Mitigation strategies for waste elimination and cost reduction in the manufacture of Bowden cables"],"prefix":"10.1007","volume":"137","author":[{"given":"Lu\u00eds","family":"Koch","sequence":"first","affiliation":[]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8570-4362","authenticated-orcid":false,"given":"Francisco Jos\u00e9","family":"Gomes da Silva","sequence":"additional","affiliation":[]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4167-4434","authenticated-orcid":false,"given":"Raul Duarte Salgueiral Gomes","family":"Campilho","sequence":"additional","affiliation":[]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2228-5348","authenticated-orcid":false,"given":"Jos\u00e9 Carlos","family":"Vieira de S\u00e1","sequence":"additional","affiliation":[]},{"ORCID":"https:\/\/orcid.org\/0000-0003-4490-1903","authenticated-orcid":false,"given":"Rafael","family":"Resende Lucas","sequence":"additional","affiliation":[]},{"ORCID":"https:\/\/orcid.org\/0000-0002-2160-0609","authenticated-orcid":false,"given":"Rita de C\u00e1ssia Mendon\u00e7a","family":"Sales-Contini","sequence":"additional","affiliation":[]}],"member":"297","published-online":{"date-parts":[[2025,3,18]]},"reference":[{"key":"15367_CR1","doi-asserted-by":"publisher","unstructured":"Heneric O, Licht G, Lutz S, Urban W (2005) The European Automotive Industry in a Global Context. https:\/\/doi.org\/10.1007\/3-7908-1644-2_2","DOI":"10.1007\/3-7908-1644-2_2"},{"key":"15367_CR2","doi-asserted-by":"publisher","unstructured":"Saberi B (2018) The role of the automobile industry in the economy of developed countries. 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