This paper explains a Kaizen approach to improve fuel economy of the Vehicle. This approach depends on discovering and plugging various energy drains, thereby improving performance of the vehicle without much cost escalation. Contrary to the common belief most of the improvements also result in improved drivability. Even though the improvements achieved by the individual Kaizen may not be significant but when aggregated they produce commendable improvements. The combination of High Fuel-economy with Low initial cost demanded by compact car segment customer is difficult to achieve but it is possible with Kaizen approach.
A comprehensive test strategy is also explained for every Kaizen involved to test the vehicle performance, durability and to generate comprehensive and comparable database for further development.