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This paper presents an in-house quality improvement methodology, built on the DMAIC structure and reported in the standardised 6-Panel format, adapted to the launch phase of a new vehicle model. The original elements of the approach are: (i) the preventive application of Six Sigma tools as early as the functional testing stage (Functional Build), before series production; (ii) twolevel validation of the measurement system, internal (Gage R&R) and at the supplier (reference metrology); (iii) capability assessment stratified by LHD/RHD configuration; (iv) the introduction of a distinct virtual validation phase, based on Moldflow simulations, between Analyse and Improve; (v) a system of six decision gates with quantitative criteria. The methodology was applied to an injection-moulded rear cover in which the gap between two components exceeded the specified tolerance. The corrective actions (redefined parameters, a local thickness reduction of about 1.5 mm and the introduction of a third injection point) reduced DPMO and increased Cpk.