Use of Selected Tools of Quality Improvement in a Company Producing Parts for the Automotive Industry – Case Study

Use of Selected Tools of Quality Improvement in a Company Producing Parts for the Automotive Industry – Case Study

KNOP Krzysztof

download PDF

Abstract. The article is a case study on the use of selected quality management tools in a company from the automotive industry for the purpose of improving the basic production process carried – the assembly process. Quality tools such as Pareto-Lorenz diagram, Ishikawa diagram, and 5WHY method were used. The analyses carried out with the use of quality tools made it possible to identify non-conformities that most often occurred during the assembly process of the tested products, indicate the causes of these non-conformities, and develop suggestions for improvement. The most frequently found non-compliance of products was the disconnection of an element during assembly, due to damage to materials in the warehouse. The root cause turned out to be the lack of control of the state of materials available in the warehouse according to the control plans in force at the plant. The need to introduce changes in the organization of warehouse work, in particular, to increase supervision over the control of the condition of materials and to introduce 100% control of products manufactured in the plant, was indicated as improvement measures.

Quality Management, Quality Tools, Improvement, Automotive Industry

Published online 9/1/2023, 10 pages
Copyright © 2023 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: KNOP Krzysztof, Use of Selected Tools of Quality Improvement in a Company Producing Parts for the Automotive Industry – Case Study, Materials Research Proceedings, Vol. 34, pp 344-353, 2023


The article was published as article 40 of the book Quality Production Improvement and System Safety

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] D. Hoyle. Quality Management Essentials. 1st Edition, Butterworth-Heinemann, New York, 2007. ISBN 978-0750667869
[2] L. Carpinetti et al. Quality management and improvement: A framework and a business-process reference model, Bus. Proc. Manag. J. 9 (2003) 543-554.
[3] M. Mas-Machuca et al. Quality management: a compulsory requirement to achieve effectiveness, Total Qual. Manag. Bus. Excell. 32 (2018) 1-20.
[4] M. Potkany et al. Influence of Quality Management Practices on the Business Performance of Slovak Manufacturing Enterprises, Acta Polytech. Hungarica 17 (202) 161-180.
[5] M. Potkany et al. Nature and Potential Barriers of Facility Management in Manufacturing Enterprises, Pol. J. Manag. Stud. 23 (2021) 327-340.
[6] G. Smith. The meaning of quality, Total Qual. Manag. 4 (1993) 235-244.
[7] S. Zembski, R. Ulewicz. Managing the Process of Adjusting the Competences of Employees Aged Forty or Over to the Requirements of Industry 4.0, Technical Transactions 119 (2022) art. e2022015.
[8] Z. Stacho et al. The Organizational Culture as a support of Innovation Processes´ Management: A Case Study, Int. J. Qual. Res. 10 (2016), 769-783.
[9] S. Borkowski et al. The use of 3×3 matrix to evaluation of ribbed wire manufacturing technology, METAL 2012 – 21st Int. Conf. Metallurgy and Materials (2012), Ostrava, Tanger 1722-1728.
[10] K. Czerwinska et al. Improving quality control of siluminial castings used in the automotive industry, METAL 2020 29th Int. Conf. Metall. Mater. (2020) 1382-1387.
[11] A. Pacana et al. Analysis of quality control efficiency in the automotive industry, Transp. Res. Procedia 55 (2021) 691-698.
[12] A. Maszke et al. Problems in the implementation of the lean concept at a steel works – Case study, MATEC Web of Conf. 183 (2018) art.01014.
[13] T. Lipinski, J. Pietraszek. Influence of animal slurry on carbon C35 steel with different microstructure at room temperature, Engineering for Rural Development 21 (2022) 344-350.
[14] T. Lipiński, J. Pietraszek. Corrosion of the S235JR Carbon Steel after Normalizing and Overheating Annealing in 2.5% Sulphuric Acid at Room Temperature, Mater. Res. Proc. 24 (2022) 102-108.
[15] S. Marković et al. Exploitation characteristics of teeth flanks of gears regenerated by three hard-facing procedures, Materials 14 (20210 art. 4203.
[16] P. Regulski, K.F. Abramek The application of neural networks for the life-cycle analysis of road and rail rolling stock during the operational phase, Technical Transactions 119 (2022) art. e2022002.
[17] N. Radek et al. The impact of laser welding parameters on the mechanical properties of the weld, AIP Conf. Proc. 2017 (2018) art.20025.
[18] N. Radek et al. Properties of Steel Welded with CO2 Laser, Lecture Notes in Mechanical Engineering (2020) 571-580.
[19] R. Ulewicz et al. Structure and mechanical properties of fine-grained steels, Period. Polytech. Transp. Eng. 41 (2013) 111-115.
[20] P. Jonšta et al. The effect of rare earth metals alloying on the internal quality of industrially produced heavy steel forgings, Materials 14 (2021) art.5160.
[21] T. Lipinski, J. Pietraszek, A. Wach. Influence of oxygen content in medium carbon steel on bending fatigue strength, Engineering for Rural Development 21 (2022) 351-356.
[22] N. Radek et al. Technology and application of anti-graffiti coating systems for rolling stock, METAL 2019 28th Int. Conf. Metall. Mater. (2019) 1127-1132. ISBN 978-8087294925
[23] N. Radek, K. Bartkowiak. Laser Treatment of Electro-Spark Coatings Deposited in the Carbon Steel Substrate with using Nanostructured WC-Cu Electrodes, Physics Procedia 39 (2012) 295-301.
[24] N. Radek et al. The effect of laser treatment on operational properties of ESD coatings, METAL 2021 30th Ann. Int. Conf. Metall. Mater. (2021) 876-882.
[25] N. Radek et al. The impact of laser processing on the performance properties of electro-spark coatings, 14th World Congress in Computational Mechanics and ECCOMAS Congress 1000 (2021) 1-10.
[26] N. Radek et al. Microstructure and tribological properties of DLC coatings, Mater. Res. Proc. 17 (2020) 171-176.
[27] N. Radek et al. The WC-Co electrospark alloying coatings modified by laser treatment, Powder Metall. Met. Ceram. 47 (2008) 197-201.
[28] N. Radek et al. The influence of plasma cutting parameters on the geometric structure of cut surfaces, Mater. Res. Proc. 17 (2020) 132-137.
[29] P. Kurp, H. Danielewski. Metal expansion joints manufacturing by a mechanically assisted laser forming hybrid method – concept, Technical Transactions 119 (2022) art. e2022008.
[30] M. Zenkiewicz et al. Electrostatic separation of binary mixtures of some biodegradable polymers and poly(vinyl chloride) or poly(ethylene terephthalate), Polimery/Polymers 61 (2016) 835-843.
[31] M. Zenkiewicz et al. Modeling electrostatic separation of mixtures of poly(ϵ-caprolactone) with polyfvinyl chloride) or polyfethylene terephthalate), Przemysl Chemiczny 95 (2016) 1687-1692.
[32] J. Pietraszek et al. The principal component analysis of tribological tests of surface layers modified with IF-WS2 nanoparticles, Solid State Phenom. 235 (2015) 9-15.
[33] J. Pietraszek, E. Skrzypczak-Pietraszek. The uncertainty and robustness of the principal component analysis as a tool for the dimensionality reduction. Solid State Phenom. 235 (2015) 1-8.
[34] R. Dwornicka, J. Pietraszek. The outline of the expert system for the design of experiment, Prod. Eng. Arch. 20 (2018) 43-48.
[35] J. Pietraszek et al. Challenges for the DOE methodology related to the introduction of Industry 4.0. Prod. Eng. Arch. 26 (2020) 190-194.
[36] J. Pietraszek. The modified sequential-binary approach for fuzzy operations on correlated assessments, LNAI 7894 (2013) 353-364.
[37] A. Goroshko et al. Construction and practical application of hybrid statistically-determined models of multistage mechanical systems, Mechanika 20 (2014) 489-493.
[38] R. Ulewicz, M. Mazur. Economic aspects of robotization of production processes by example of a car semi-trailers manufacturer, Manufacturing Technology 19 (2019) 1054-1059.
[39] N. Radek, R. Dwornicka. Fire properties of intumescent coating systems for the rolling stock, Commun. – Sci. Lett. Univ. Zilina 22 (2020) 90-96.
[40] A. Bakowski et al. Frequency analysis of urban traffic noise, ICCC 2019 20th Int. Carpathian Contr. Conf. (2019) 1660-1670.
[41] J.M. Djoković et al. Selection of the Optimal Window Type and Orientation for the Two Cities in Serbia and One in Slovakia, Energies 15 (2022) art.323.
[42] W. Przybył et al. Virtual Methods of Testing Automatically Generated Camouflage Patterns Created Using Cellular Automata, Mater. Res. Proc. 24 (2022) 66-74.
[43] N. Radek et al. Operational tests of coating systems in military technology applications, Eksploat. i Niezawodn. 25 (2023) art.12.
[44] W. Przybył et al. Microwave absorption properties of carbonyl iron-based paint coatings for military applications, Def. Technol. 22 (2023) 1-9.
[45] D.R. Bamford, R.W. Greatbanks. The use of quality management tools and techniques: a study of application in everyday situations, Int. J. Qual. Rel. Manag. 22 (2005) 376–392.
[46] K. Knop. Analysis and Quality Improvement of the UV Printing Process on Glass Packaging, Qual. Prod. Improv. 3 (2021) 314–325.
[47] G. Paliska, D. Pavletic, M. Sokovic. Quality tools – systematic use in process industry, J. Achiev. Mater. Manuf. Eng. 25 (2007) 79-82.
[48] A. Pacana, R. Ulewicz. Analysis of causes and effects of implementation of the quality management system compliant with ISO 9001, Pol. J. Manag. Stud. 21 (2020) 283-296.
[49] J. Tarí, V. Sabater. Quality tools and techniques: Are they necessary for quality management? Int. J. Prod. Econ. 92 (2004) 267-280.
[50] K. Knop, R. Ulewicz. Solving Critical Quality Problems by Detecting and Eliminating their Root Causes – Case-Study from the Automotive Industry, Mater. Res. Proc. 24 (2022) 181-188.
[51] R. Ulewicz et al. Logistic Controlling Processes and Quality Issues in a Cast Iron Foundry, Mater. Res. Proc. 17 (2020) 65-71.
[52] M. Krynke. The Use of Computer Simulation Techniques in Production Management, Mater. Res. Proc. 24 (2022) 126-133.