Purpose: The article presents an analysis of the application of selected quality management methods and tools in order to identify factors affecting downtimes in the production line, illustrated with an example of the automotive industry.
Methodology/Approach: The paper contains an analysis of downtimes in the production process using selected methods and tools of quality management. The authors used a combination of tools and methods to carry out the analysis. In this concept, first, the 5WHY method and the Ishikawa diagram were used.
Findings: The research results presented in the paper suggest that better results can be achieved by using a set of quality tools instead of one particular tool. The authors found that using a wide range of quality tools can be useful to reduce downtimes on the production line.
Research limitation/implication: The major limitation of the paper is that it is based on one case of an organisation from the automotive industry. In the future, it will be necessary to conduct studies in more organisations so as to find out if the same result can be achieved.Originality/Value of paper: The article is concerned with the use of quality management methods and tools to analyse production line breakdowns. Until present, in subject literature, the causes of downtimes have been analysed without differentiating between planned and unplanned downitmes of the production line.
Bamford, D.R. and Greatbanks, R.W., 2005. The use of quality management tools and techniques: a study of application in everyday situations. International Journal of Quality & Reliability Management, [e-journal 22(4), pp.376-392. http://dx.doi.org/10.1108/02656710510591219.
Bandyopadhyay, J.K., 2007. Six Sigma Approach of Quality Assurance in Global Supply Chains: A Study of United States Automakers. International Journal of Management, [online] Available at: < https://www.questia.com/library/journal/1P3-1278577441/six-sigma-approach-to-quality-assurance-in-global > [Accessed 30 July 2019].
Battini, D., Persna, A., Sgarbosa, F., Zennaro, L. and Marchi, R., 2015. Downtime Analysis as a tool to improve efficiency in automated production lines. In: Summer School Francesco Turco, XX Summer School Francesco Turco - Industrial Systems Engineering. Naples, Italy, 16-18 September 2015. pp.162-170.
Bokrantz, J., Skoogh, A., Ylipaa, T. and Stahre, J., 2016. Handling of production disturbances in the manufacturing industry. Journal of Manufacturing Technology Management, [e-journal] 27(8), pp.1054-1075. https://doi.org/10.1108/JMTM-02-2016-0023.
Bunney, H.S. and Dale, B.G., 1997. The implementation of quality management tools and techniques: a study. The TQM Magazine, [e-journal] 9(3), pp.183-189. https://doi.org/10.1108/09544789710168966.
Dale, B.G., 2003. Managing Quality. 4th ed.. Oxford: Blackwell Publishers.
Dale, B.G. and McQuater, R.E., 1998. Managing Business Improvement and Quality: Implementing Key Tools and Techniques. Oxford: Blackwell Publishers.
Delbridge, R. and Barton, H., 2007. Organizing for continuous improvement. Structures and roles in automotive components plants. International Journal of Operations & Production Management, [e-journal] 22(6), pp.680-692. https://doi.org/10.1108/01443570210427686.
Evans, J.R. and Lindsay, W.M., 1999. The Management and Control of Quality. 4th ed.. Cincinnati: South-Western College Publishing.
Hussan, S.A., Lundberg, J., Wijaya, A. and Nehzad, G., 2014. Downtime analysis of drilling machines and suggestions for improvements. Journal of Quality in Maintenance Engineering, [e-journal] 20(4), pp.306-332. https://doi.org/10.1108/JQME-11-2012-0038.
Hys, K., 2014. Tools and methods used by the Polish leading automotive companies in quality management system. Results of empirical research. International Journal of Materials and Manufacturing, 63(1), pp.30-37.
Imai, M., 2007. KAIZEN. Kaizen: Kaizen Institute, MT Business Ltd..
Knezevic, J., 1994. Determination of Operations/Production Downtime for Group Replacement Maintenance Policy. International Journal of Operations & Production Management, [e-journal] 14(7), pp.18-26. https://doi.org/10.1108/01443579410062130.
Liker, J.K. and Hoseus, M., 2009. Kultura Toyoty. Warszawa: MT Biznes Ltd..
Liker, J.K. and Meier, D.P., 2008. Toyota talent. Warszawa: MT Biznes Ltd..
Lin, W.T., Liu, C.H., Hsu, IC. and Lai, C.T., 2004. An Empirical Study of QS 9000 in the Automobile and Related Industries in Taiwan. Total Quality Management and Business Excellence, [e-journal] 15(3), pp.355-378. https://doi.org/10.1080/1478336042000183424.
Łuczak, J. and Wolniak, R., 2015. Problem-solving and developing quality management methods and techniques on the example of automotive industry. Manager Journal, 22(1), pp.237-250.
Nazrul, J.I., Kumar, H.M. and Datta, R., 2012. A Study on Job Satisfaction and Morale of Commercial Banks in Bangladesh. International Journal of Economics and research, 4(Jul-Aug), pp.153-173.
Putri, N.T. and Yusof, S.M., 2008. A Review of Quality Engineering Tools and Techniques Practices in Malaysia’s and Indonesia’s Automotive Industries and an Agenda for Future Rese. ICMIT, 4th IEEE International Conference Management of Innovation and Technology. Bangkok, Thailand, 21-24 September 2008. IEEE. https://doi.org/10.1109/ICMIT.2008.4654407.
Sila, I., Ebrahimpour, M. and Birkholz, Ch., 2006. Quality in supply chains: an empirical analysis. Supply Chain Management, [e-journal] 11(6), pp.491-502. https://doi.org/10.1108/13598540610703882.
Silombela, T. and Mutingi, M., 2018. Impact of quality management tools and techniques: Case of Namibian municipal water distributors. Journal of Quality in Maintenance Engineering, 24(1), pp.2-21.
Skotnicka-Zasadzień, B., 2013. Application of quality engineering elements for the improvement of production processes - case study. ICIEMS, International Conference on Industrial Engineering and Management Science. Shanghai, China, 28-29 September 2013. ICIEMS. pp.362-368.
Skotnicka-Zasadzień, B., Wolniak, R. and Zasadzień, M., 2017. Use of quality engineering tools and methods for the analysis of production processes - case study. FEBM, Proceedings of the Second International Conference on Economic and Business Management. Shanghai, China, 21-23 October 2017. Piman Limpaphayom, Gordon Huang: Atlantis Press. pp.240-245.
Stal, Ch., Gabrielson, P., Andersson, C. and Stahl, J.E., 2012. A production performance analysis regarding downtime and downtime pattern. FAIM, 22nd International Conference on Flexible Automation and Intelligent Manufacturing. 2012, Helsinki, Finland, 17 October 2011. Helsinki: Lund University.
Thia, C.W., Chai, K.H., Bauly, J. and Xin, Y., 2005. An exploratory study of the use of quality tools and techniques in product development. The TQM Magazine, [e-journal] 17(5), pp.406-424. https://doi.org/10.1108/09544780510615924.
Wilkinson, A. and Willmott, H. eds., 1995. Making quality critical: new perspectives on organizational change, London, United Kingdom: Routledge.
Wolniak, R., 2014. Relationship between selected lean management tools and innovations. Zeszyty Naukowe, 75, pp.157-266.
Wolniak, R. and Skotnicka-Zasadzień, B., 2014. The use of value stream mapping to introduction of organizational innovation in industry. Metalurgija, 53(4), pp.709-712.
Zasadzień, M., 2017. Application of the Six Sigma method for improving maintenance processes - case study. ICORES, 6th International Conference on Operations Research and Enterprise Systems. Porto, Portugal, 23-25 February 2017. Setúbal: Science and Technology Publications.
Zennaro, I., Batiini, D., Sgarbossa, F., Persona, A. and Marchi, R., 2018. Micro downtime: Data collection, analysis and impact on OEE in bottling lines the San Benedetto case study. International Journal of Quality & Reliability Management, 34(4), pp.965-995.
Żuchowski, J. and Łagowski, E., 2004. Narzędzia i metody doskonalenia jakości. Radom: Politechnika Radomska.