Use of quality engineering tools and methods for the analysis of production processes - case study

Abstract

The article presents the application of selected quality engineering methods for solving a problem with product quality in the production process of plastic bags. Defects present in the product were identified and hierarchized by the number of defects in the total production volume. Next, using the Ishikawa diagram, the main causes for the occurrence of the most significant defect, i.e. "foil sticking together" were identified. The scale of the problem for the various causes was determined using FMEA, corrective and preventive measures were proposed and their effectiveness estimated. Thanks to the analysis it was possible to take actions which lead to a decrease in the number of faulty products and introducing preventive measures to reduce the risk of problems occurring in the future.

Downtime in the Automotive Industry Production Process – Cause Analysis

“…This standard outlines the specific requirements for the application of ISO 9001:2015 in automotive production and relevant service part organizations (Lin et al, 2004). This standard recognizes the uniqueness of every automotive supplier's process, while providing critical tools to help your company better meet customer specific requirements (Bakhtiar, Mohammad and Kazemzadeh, 2010;Wolniak, 2014;Skotnicka-Zasadzień, Wolniak and Zasadzień, 2017;Thia et al, 2005).…”

“…A significant number of those methods are called systems, because they constitute an integral and necessary element of cooperation between organisations in the customer-supplier relations, (Liker and Hoseus 2009;Bandyopadhyay, 2007;Delbridge and Barton, 2007;Liker and Meier, 2008;Sila, Ebrahimpour and Birkholz, 2006;Żuchowski and Łagowski, 2004;Imai, 2007;Nazrul, Kumar and Datta, 2012;Łuczak and Wolniak, 2015;Wolniak and Skotnicka-Zasadzień, 2014;Skotnicka-Zasadzień, 2013).…”

Improving Production Efficiency of Large Size Molds as a Result of Innovative Quality Control Process

“…On the other hand, the development of the market of specialist products requires that customers have technologically advanced devices for quality control processes. Production processes, associated with the manufacture of large-size molds with a weight of, say, 30 tons, are conditioned, among others, by the possibility of precise verification and adjustment of the mold after the machining process in order to achieve the highest possible manufacturing quality (Hamrol and Mantura, 2005;Skotnicka-Zasadzien et al, 2017;Zasadzien and Midor, 2015). Therefore, in both the quality control departments and in the R&D departments of companies which manufacture large-size elements, specialist innovative tools (both measuring and verifying the correctness of the manufacture of molds) need to be used.…”

Use of IT technologies in the management of production process quality

“…The reasons and effects of product nonconformities are defined and errors in the course of the production process are identified using production management support systems. Application of IT systems provides tangible benefits, which contribute to reduced costs of product manufacturing [15]. Following changes in the value of components of the technical production cost structure enables evaluating a defective product, taking into account both the time of the defect occurrence and the duration of its forming.…”

“…Based on numerous studies regarding production costs analysis, one can conclude that failure to meet quality requirements is frequently a source of additional costs, causing unexpected financial losses for the enterprise [10,11]. Actions that eliminate the identified nonconformities, but, at the same time, generate additional costs, include [12]:  correction of errors, involving the necessity to use additional materials, raw materials or utilities, as well as the use of different tools, etc.…”