The Synergy Model of Quality Tools and Methods and Its Influence on Process Performance and Improvement

Abstract

Implementing quality tools and methods creates a basic foundation for innovations, sustainability, optimization, and competitiveness in the era of Industry 4.0 and Quality 4.0. This paper aimed to investigate the use of quality tools and methods in the 24 divisions of a mother manufacturing company without the influence of external factors such as geographical location (America, Africa, Asia, and Europe). It was important for the mother manufacturing company to implement a uniform process standard for innovation and performance. Research methods focused on using the Kanban card, Ishikawa diagram, affinity diagram, Flowchart, 5S, OPL, layout, and Pareto analysis. It was determined in this research that the synergy (combination) of quality tools and methods in divisions improves the process performance. This hypothesis was confirmed by the results of implementing quality tools in processes within divisions. A top result was the new innovative model of synergy of the quality tools and methods for divisions of the parent company thus filling a gap in the scientific field. This model created the basis for the uniform process standard in all divisions. The results brought improvements in the processes such as material input inspection, spare parts production, production process, and product packaging. This model could be a proactive instrument for process innovation.