Wyniki wyszukiwania - BazTech

1

Redukcja czasu przezbrojenia maszyn z wykorzystaniem metody SMED w wybranym przedsiębiorstwie produkcyjnym

Dąbrowska Magdalena, Jokiel Paweł

Gospodarka Materiałowa i Logistyka

|

2023

|

nr 2

38--49

PL

Obecnie przedsiębiorstwa produkcyjne funkcjonują w turbulentnym otoczeniu, co jest następstwem m.in. kryzysu światowego wywołanego przez pandemię i wojnę. Z tego względu są zmuszone do ciągłego poszukiwania rozwiązań umożliwiających obniżanie kosztów produkcyjnych, skracania czasu reakcji na potrzeby rynkowe czy wprowadzanie innowacyjnych rozwiązań z zakresu doskonalenia procesów produkcyjnych. Nowe spojrzenie na realizowane procesy produkcyjne zostało wymuszone przez zmieniające się i stale rosnące wymagania rynku oraz możliwość implementacji innowacyjnych rozwiązań techniczno-organizacyjnych. Zadaniem usprawnienia procesu produkcyjnego jest eliminacja strat i poszukiwanie źródeł marnotrawstwa, a także standaryzacja zaimplementowanych rozwiązań. Jednym ze sposobów poprawy efektywności i elastyczności procesów produkcyjnych jest koncepcja Lean, nastawiona na eliminację marnotrawstwa oraz skracanie cykli realizacji zamówienia w procesie. Do najważniejszych narzędzi stosowanych w koncepcji Lean Management należą: 5S, Kaizen, Just in Time, Just in Sequence, Kanban (system pull), Single Minute Exchange of Die (SMED), Total Productive Maintenance (TPM), Value Stream Mapping (VSM), standaryzacja, muda, Total Quality Management (TQM), takt time, heijunka, andon (Visual Management), poka yoke. Celem opracowania jest redukcja czasu przezbrojenia maszyny wykrawającej w procesie produkcji maty bitumicznej z zastosowaniem metody SMED.

EN

Currently, production companies operate in a turbulent environment as a result, among others, of the global crisis caused by the pandemic and war. For this reason, they are forced to constantly search for solutions in the field, e.g., lowering production costs, shortening reaction time in response to market needs, or introducing innovative solutions to improve production processes. A new look at the production processes implemented was forced by the changing and constantly growing market requirements and the possibility of implementing innovative technical and organizational solutions. The task of streamlining the production process is the elimination of losses and the search for waste sources and standardizing the implemented solutions. One of the ways to improve the efficiency and flexibility of production processes is the Lean concept, which is focused on eliminating waste and shortening order fulfilment cycles in the process. The essential tools used in the Lean Management concept include: 5S, Kaizen, Just in Time, Just in Sequence, Kanban (pull system), Single Minute Exchange of Die (SMED), Total Productive Maintenance (TPM), Value Stream Mapping (VSM), standardization, muda, Total Quality Management (TQM), tact time, heijunka, andon (Visual Management), poka yoke. The paper aims to reduce the changeover time of the punching machine in the bitumen mat production process based on the use of the SMED method.

2

Improvement of the production process using Lean Management - case study

Jakubiec Marcin

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

|

2022

|

z. 158

229--242

EN

Purpose: The aim of the article is to present the benefits of using selected Lean Management elements in the production process on the example of a company producing mechanical seals. Design/methodology/approach: The article is theoretical and empirical in nature and is based on the analysis of a selected case. In the empirical part, the analysis concerns selected elements of the production process in the examined enterprise. Findings: The results obtained in the article refer to the benefits of using Lean Management in the production process in the analyzed enterprise. The use of identification and elimination of waste and standardization of activities at workplaces (introduction of job instructions) in selected areas of the production process allowed for the improvement of its parameters, which was presented in the article. Research limitations/implications: The limitations in the empirical area could be the reference only to selected aspects of Lean Management and the analyzed process. Future research will cover the broader scope of Lean Management and other companies. Practical implications: The results of the case study show the direct impact of Lean Management on the parameters of the analyzed production process. Thanks to the use of Lean Management, the process parameters have improved, which is an important factor in the context of the effectiveness of the company's functioning as a system. Originality/value: The added value of the article is the practical presentation of the use of Lean Management to improve the parameters of the production process.

3

Zastosowanie logiki rozmytej do szeregowania zleceń produkcyjnych

Jardzioch Andrzej, Witkowska Weronika

Zarządzanie Przedsiębiorstwem

|

2022

|

Vol. 25, nr 3-4

15--20

EN

The article presents an algorithm that allows using fuzzy logic to determine the effective arrangement of production orders in the production system. The main criterion used to rate was the total cost related to delayed implementation of production orders. In addition, the sum of delays of all orders and the total time of order execution were assessed. The elaborated algorithm uses fuzzy inference and allows us to estimate dynamically the effectiveness of selecting the next order from orders awaiting execution. As a result, the computational complexity of the proposed algorithm is linear. The research was conducted to assess the usefulness of the proposed algorithm. To illustrate the possibilities of the proposed algorithm, the obtained rankings were compared with those obtained using typical heuristic rules (FIFO, EDD, Johnson’s algorithm, and min changeover time). The obtained results confirmed the benefits of the proposed algorithm for scheduling production orders. The developed algorithm was implemented in Matlab and research was carried out for different series of production orders.

4

Reorganization of the assembly station in the production process of the sliding floor for reloading ramps in the context of improving the quality of the finished product

Dąbrowska Magdalena, Medyński Daniel, Bieliński Wiktor, Kolbusz Krzysztof

Technologia i Automatyzacja Montażu

|

2022

|

nr 3

28--35

EN

The paper presents the definitions of the term quality quoted in the literature on the subject. FMEA (Failure Mode and Effects Analysis) methodology was presented. A reloading ramp was characterized as the subject of the study. A cause-and-effect analysis of non-compliance in the finished product was performed using the Pareto-Lorenz diagram, Ishikawa diagram and brainstorming. The FMEA analysis of the assembly table indicated the elements of the workstation causing the most frequently occurring non-conformities. Based on the obtained results, corrective actions were proposed to reorganize the assembly station. The implemented activities made it possible to reduce the critical RPN coefficients for the elements of the assembly table and to shorten the time necessary to make one piece of the finished product.

PL

W artykule przedstawiono definicje pojęcia jakość przytaczane w literaturze przedmiotu. Zaprezentowano metodykę FMEA (Failure Mode and Effects Analysis). Scharakteryzowano rampę przeładunkową jako przedmiot badań. Dokonano analizy przyczynowo-skutkowej powstawania niezgodności w wyrobie gotowym z wykorzystaniem diagramu Pareto-Lorenza oraz diagramu Ishikawy i burzy mózgów. Dzięki przeprowadzonej analizie FMEA stołu montażowego wskazano elementy stanowiska powodujące najczęściej powstające niezgodności. Na podstawie uzyskanych wyników zaproponowano działania korygujące, mające na celu reorganizacje stanowiska montażu. Wdrożone działania naprawcze umożliwiły obniżenie krytycznych współczynników RPN w elementach stołu montażowego oraz skrócenie czasu niezbędnego do wykonania jednej sztuki wyrobu gotowego na stanowisku montażu.

5

Optimising the sealing station in production process of tubes for catalytic converters involving SMED method - a case study

Dąbrowska Magdalena, Maciejewska Katarzyna

Technologia i Automatyzacja Montażu

|

2022

|

nr 2

15--23

EN

The article presents the stages of the development of the lean management concept. The authors presented the SMED methodology. They made the analysis of the sealing station in the production process of tubes for catalytic converters in relation to the real model. Optimisation the sealing station in production process of tubes for catalytic converters has been done in this article. For this purpose was used one of the tools of Lean Manufacturing, SMED. Diagnosis of machine changeover operations was carried out and also measurement of the times necessary for doing these operations. Using spaghetti diagram, the path which is covered by the operator during machine changeover, was shown. Delegation of specific tasks carried out previously by the operator to production workers and implementation of organisational and technical solution has had the effect of relieving of the operator and shortening of time necessary for machine changeover and increasing productivity at the sealing station.

PL

W artykule przedstawiono etapy rozwoju koncepcji lean management. Autorki zaprezentowały metodologię SMED. Dokonały analizy stanowiska uszczelniania w procesie produkcyjnym przewodów do katalizatorów w odniesieniu do modelu rzeczywistego. W artykule dokonano optymalizacji stanowiska uszczelniania w procesie produkcyjnym przewodów do katalizatorów. W tym celu zastosowano jedno z narzędzi Lean Production, a mianowicie SMED. Dokonano diagnozy czynności wykonywanych podczas przezbrajania maszyny oraz dokonano pomiaru czasów niezbędnych do wykonania wskazanych czynności. Wykorzystując diagram spaghetti zilustrowano drogę, którą pokonuje operator podczas przezbrojenia maszyny. Oddelegowanie wybranych czynności wykonywanych uprzednio przez operatora na obsługę produkcji oraz wprowadzenie rozwiązania organizacyjno-technicznego wpłynęło na odciążenie operatora i skrócenie czasu niezbędnego do przezbrojenia maszyny i zwiększenia produktywności na stanowisku uszczelniania.

6

Analysis of the possibility of using the D3 discipline of the G8D method in solving quality management problems for NOK products

Cyganiuk Joanna, Idzikowski Adam, Kuryło Piotr, Tertel Edward

System Safety : Human - Technical Facility - Environment

|

2022

|

Vol. 4, nr 1

196-204

EN

In the paper the D3 discipline of the G8D method has been presented. In the presented procedure all decisions are made regarding the introduction of interim corrective actions - ICA. The algorithm of conduct for the discipline and the quality management tools that the discipline uses have been also presented. It has been also discusses how to proceed for the D3 discipline in determining temporary corrective actions for the NOK detail with the preceding actions in the D2 discipline.

7

Prądy błądzące a utrzymanie ruchu

Nowicki Ryszard

Napędy i Sterowanie

|

2022

|

R. 24, nr 11

41--58

PL

Problematyka utrzymania ruchu (UR), w szczególności dla maszyn i urządzeń krytycznych oraz tych innych, które mają duże znaczenie dla realizowanego procesu produkcyjnego, jest nierozerwalnie związana z potrzebą oceny stanu technicznego. Jedną z przyczyn prowadzących do przyspieszonej utraty integralności mechanicznej są pasożytnicze efekty elektryczne, zwane też błądzącymi: napięcia błądzące i prądy błądzące... [wprowadzenie]

8

Scheduling of the Manufacturing Cell Work with the Use of a Genetic Algorithm on the Example of a Flexible Production System

Matuszny Marcin

Management and Production Engineering Review

|

2022

|

Vol. 13, No. 4

98--106

EN

The article is to present the application of genetic algorithm in production scheduling in a production company. In the research work the assumptions of the methodology were described and the operation of the proposed genetic algorithm was presented in details. Genetic algorithms are useful in complex large scale combinatorial optimisation tasks and in the engineering tasks with numerous limitations in the production engineering. Moreover, they are more reliable than the existing direct search algorithms. The research is focused on the effectivity improvement and on the methodology of scheduling of a manufacturing cell work. The genetic algorithm used in the work appeared to be robust and fast in finding accurate solutions. It was shown by experiment that using this method enables obtaining schedules suitable for a model. It gives a group of solutions that are at least as good as those created by the heuristic rules.

9

Modelling information for the burnishing process in a cyber-physical production system

Patalas-Maliszewska Justyna, Posdzich Marco, Skrzypek Katarzyna

International Journal of Applied Mathematics and Computer Science

|

2022

|

Vol. 32, no. 3

345--354

EN

Currently, the manufacturing management board applies technologies in line with the concept of Industry 4.0. Cyber-physical production systems (CPSs) mean integrating computational processes with the corresponding physical ones, i.e., allowing work at the operational level and at the strategic level to run side by side. This paper proposes a framework to collect data and information from a production process, namely, the burnishing one, in order to monitor real-time deviations from the correct course of the process and thus reduce the number of defective products within the manufacturing process. The proposed new solutions consist of (i) the data and information of the production process, acquired from sensors, (ii) a predictive model, based on the Hellwig method for errors in the production process, relying on indications of a machine status, and (iii) an information layer system, integrating the process data acquired in real time with the model for predicting errors within the production process in an enterprise resource planning (ERP) system, that is, the business intelligence module. The possibilities of using the results of research in managerial practice are demonstrated through the application of an actual burnishing process. This new framework can be treated as a solution which will help managers to monitor the production flow and respond, in real time, to interruptions.

10

Tools of product quality planning in the production part approval process

Rudolf Ł., Roszak M.

Archives of Materials Science and Engineering

|

2022

|

Vol. 118, nr 2

67--74

EN

Purpose: The article concerns the analysis of the applicable normative requirements in the field of product quality planning in the process of approving parts for production. Design/methodology/approach: The analysis, in particular, concerns the correlation of appropriate methods and quality management tools in the quality planning process. Findings: Correct use of quality planning tools in product and process development determines the effectiveness of implementing individual phases of APQP (Advanced Product Quality Planning). Research limitations/implications: It is important that the organisation skilfully and consciously uses the quality tools required by APQP; they usually require multiple uses during the project implementation time, which depends on the specificity of a particular project. Practical implications: The study presents how core quality planning tools are related, proving that they cannot be treated as an individual tool, but only their correct use can protect the project/organisation against nonconformities or misunderstandings between the supplier and the customer. Originality/value: The study's originality and novelty show the relations and dependence between APQP phases and core quality tools/evidence developed in the PPAP (Production Part Approval Process), according to PPAP level 3. The article presents a practical approach to the use or multiuse of particular core quality planning tools according to APQP phases.

11

Identification of the impact of the availability factor on the efficiency of production processes using the AHP and Fuzzy AHP

Wittbrodt Piotr, Łapuńka Iwona, Baytikenova Gulzhan, Gola Arkadiusz, Zakimova Alfiya

Applied Computer Science

|

2022

|

Vol. 18, no 4

116--129

EN

Maintenance has a key impact on the efficiency of the production processes because the efficiency of the machines determines the ability of the system to produce in accordance with the assumed schedule. The key element of the system performance assessment remains the availability of technological equipment, which directly translates into the efficiency and effectiveness of the performed production tasks. Taking into account the dynamic nature of manufacturing processes, the proper selection of machinery and equipment for the implementation of specific production tasks becomes an issue of particular importance. The purpose of this research was to determine the impact of technical and non-technical factors on the material selection of machine tools for production tasks and to develop a method of supporting the selection of production resources using the AHP and Fuzzy AHP methods. The research was carried out in a manufacturing company from the automotive industry.

12

Simulation and Optimization of Saw Blade Production in Plant Simulation

Malega Peter, Daneshjo Naqib, Rudy Vladimír, Rehák Róbert

Advances in Science and Technology. Research Journal

|

2022

|

Vol. 16, no 3

67--77

EN

This paper is oriented on very important topics, which nowadays simulation and optimization surely are. First part of this paper is oriented on simulation software Plant Simulation, because this software is one of the best software on the market. Second section deals in detail with the procedure of saw blades production. Third section presents creation of simulation model for selected production process, which is production of saw blades. Final fourth section is about proposals for improvement of saw blade production.

13

Wyznaczenie wąskiego gardła w przedsiębiorstwie branży metalurgicznej z wykorzystaniem pakietu symulacyjnego programu ARENA

Kamiński Piotr, Drobina Robert

Zeszyty Naukowe Politechniki Poznańskiej. Organizacja i Zarządzanie

|

2021

|

Nr 84

95--110

PL

W artykule przedstawiono metodykę badań przy wyznaczeniu wąskiego gardła w przedsiębiorstwie branży metalurgicznej. Na początku omówiono znaczenie metod symulacyjnych w inżynierii produkcji. Następnie scharakteryzowano proces produkcyjny wytwarzania prętów mosiężnych w wybranym przedsiębiorstwie branży metalurgicznej z uwzględnieniem specyfiki poszczególnych stanowisk roboczych w rzeczywistych warunkach produkcyjnych. Arbitralnie założono, że do opisu zachodzących zjawisk w analizowanym procesie produkcyjnym adekwatnym do rzeczywistych warunków eksploatacyjnych na poszczególnych stanowiskach produkcyjnych odpowiednie są modele statystyczne oparte na rozkładzie trójkątnym, normalnym oraz jednostajnym. Dalej podjęto próbę przedstawienia wzajemnych relacji pomiędzy istniejącymi stanowiskami produkcyjnymi oraz połączenia ich w jeden system produkcyjny. Dokonano tego, stosując pakiet symulacyjny programu ARENA. Dla tak zaproponowanego podejścia symulacja komputerowa pozwoliła na wyodrębnienie wąskiego gardła w prezentowanym procesie technologicznym wytwarzania prętów mosiężnych. Rozwiązanie teoretyczne weryfikowano metodami statystycznymi w warunkach przemysłowych, czego efektem jest propozycja sposobu zwiększenia wydajności produkcji. Przeprowadzony plan eksperymentu pozwolił na zidentyfikowanie czynności oraz oszacowanie ich wpływu na występowanie wąskiego gardła w procesie produkcyjnym.

EN

The aim of the article is to present the research methodology for determining the bottleneck in a metallurgical company. At the beginning, the importance of simulation methods in production engineering is discussed. Then, the production process of brass rods in a selected company in the metallurgical industry is characterized, taking into account the specificity of individual workstations in real production conditions. It was arbitrarily assumed that statistical models based on a triangular, normal and uniform distribution are used to describe the phenomena occurring in the analyzed production process, adequate to the actual operating conditions at individual production stations. Next, an attempt is made to present the mutual relations between the existing production stations and to combine them into one production system. This was done using the ARENA simulation model. In the proposed approach, the computer simulation allowed us to isolate the bottleneck in the presented technological process of producing brass bars. The theoretical solution was verified using statistical methods in industrial conditions, and the results show the possibility of increasing production efficiency. The conducted research identified the activities and estimated their impact on the occurrence of the bottleneck in the production process.

14

Risk Analysis on the Example of Chocolate Production®

Kowalska Jolanta, Urbańska Bogumiła, Gresse-Łyko Aleksander

Postępy Techniki Przetwórstwa Spożywczego

|

2021

|

nr 2

71--83

EN

Risk analysis is a tool supporting and allowing to determine the level of risk and the effects that may cause potential threats. Based on the results obtained, during the analysis of hazards in the chocolate production process, it was possible to assess the existing hazards and assign them a specific weight, which translates into risk levels that have a potential impact on the health safety of dark chocolates. Dark chocolate has been shown to be a relatively safe product. Many stages in the technological cycle allow for the elimination of hazards from raw materials and earlier processing stages, which is supported by properly designed quality systems.

PL

Analiza ryzyka jest narzędziem wspomagającym i pozwalającym na określenie poziomu ryzyka i skutków, jakie mogą wywołać potencjalne zagrożenia. W oparciu o uzyskane wyniki podczas analizy zagrożeń w procesie produkcji czekolady możliwe było dokonanie oceny występujących zagrożeń oraz nadanie im określonej wagi, przekładającej się na poziomy ryzyka mające potencjalny wpływ na bezpieczeństwo zdrowotne czekolad gorzkich. Wykazano, że czekolada gorzka jest produktem stosunkowo bezpiecznym. Wiele etapów w cyklu technologicznym pozwala na usunięcie zagrożeń pochodzących z surowców i wcześniejszych etapów przetwórczych, w czym są pomocne właściwie opracowane systemy jakości.

15

Robotyzacja procesów produkcyjnych. Wprowadzenie

Kaczmarek Wojciech, Panasiuk Jarosław

Napędy i Sterowanie

|

2021

|

R. 23, nr 6

74--81

PL

Robotyka jest dziedziną wiedzy technicznej zajmującą się budową robotów, ich sterowaniem, programowaniem i zastosowaniem w różnych domenach nauki i techniki. Jest interdyscyplinarna, łączy wiedzę z wielu innych dziedzin (mechaniki, automatyki, elektroniki, informatyki itp.). Dziś z łatwością można zauważyć obecność robotów w przemyśle, medycynie, transporcie, budownictwie, administracji, wojsku, rolnictwie i kosmosie. Swoje miejsce w życiu człowieka robotyka znalazła wszędzie tam, gdzie praca jest szczególnie uciążliwa, monotonna i niebezpieczna.

16

ACOPOS 6D. Nowa era produktywności

Hensel Stefan

Napędy i Sterowanie

|

2021

|

R. 23, nr 4

22--23

PL

Dzisiejsze zakłady i maszyny zajmują dużo miejsca. Ale tylko ułamek ich powierzchni ma rzeczywisty wpływ na sam proces produkcji. Znacznie większa część przestrzeni produkcyjnej przeznaczona jest do transportu produktów z miejsca na miejsce. Można jednak uwolnić się od tych ograniczeń jednowymiarowego transportu produktów i przygotować grunt pod nową erę produktywności.

17

Stochastic Simulation of Production Processes - selected issues

Snopkowski Ryszard, Sukiennik Marta, Napieraj Aneta

Inżynieria Mineralna

|

2021

|

no. 1

137--146

EN

The article presents selected issues in the field of stochastic simulation of production processes. Attention was drawn to the possibility of including, in this type of models, the risk accompanying the implementation of processes. Probability density functions that can be used to characterize random variables present in the model are presented. The possibility of making mistakes while creating this type of models was pointed out. Two selected examples of the use of stochastic simulation in the analysis of production processes on the example of the mining process are presented.

18

Some Possibilities of Using Statistical Methods While Solving Poor Quality Production

Lakomá R., Čamek L., Lichý P., Kroupová I., Radkovský F., Obzina T.

Archives of Foundry Engineering

|

2021

|

Vol. 21, iss. 1

18--22

EN

This paper presents an overview of a research on six practical cases that were solved in a precise casting company where parts are cast by the mean of the low-wax casting method (investment casting) in order to decrease poor quality production. The steel cast parts production technology by the lost-wax method requires the detailed work procedures observation. On the base of statistical processing data of given types of casting products, it was possible to assess the significance of each particular checking events by using the statistical hypothesis testing. The attention was focused on wax and ceramic departments. The data in technological flow were compared before and after the implementation of the change and statistical confirmative influences were assessed. The target consisted in setting such control manners in order to get the right conditions for decreasing poor quality parts. It was evidenced that the cast part defect cause correct identification and interpretation is important.

19

Quality management tools in the aspect of the assessment of the effectiveness of the enterprise production process in the hydraulic industry

Gruszka Sara

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

|

2020

|

z. 142

217--231

EN

Purpose: The purpose of including the following analysis was the problem diagnosed in a manufacturing company with hydraulic technology in the aspect of the growing number of hydraulic connected complaints. Therefore, a decision was made to analyze in detail the problem encountered with the available methods and tools. Design/methodology/approach: The study presents a literature approach to issues related to the effectiveness of the production process and the characteristics of the principles, methods, tools and techniques of quality management, as well as the practical application of the 5 WHY tool, based on a production enterprise from the hydraulic industry. Findings: The analysis carried out noticed problem using the Five Whys tool on the basis of data from a manufacturing enterprise from the hydraulic industry, as well as the created summaries of reasons for both quantitative and qualitative complaints in 2016 and 2017 enabled the identification of the main source of the diagnosed problem in the form of too many corroded hydraulic components in 2017 and the formulating of necessary recommendations to eliminate the above mentioned disadvantages of finished products for the enterprise. Practical implications: The introduced changes in the company from the hydraulic industry will significantly facilitate and improve the identification of defective products that should ultimately not reach the enterprise's customers. Originality/value: Formulating practical conclusions on using quality management tools in the aspect of the assessment of the effectiveness of the enterprise production process in the hydraulic industry.

20

Quality aspects of improving the production process effectiveness by eliminating critical defects

Skotnicka-Zasadzień Bożena

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

|

2020

|

z. 144

439--447

EN

Purpose: Critical defects are of great significance when evaluating the production process effectiveness, especially in the automotive branch. It is important to analyse these defects and distinguish the crucial ones. In this article, the authors have identified critical defects in the process of brake master cylinders production using quality management tools, and proposed improvement actions. Design/methodology/approach: The aim of the article was to analyse defects and the reasons for their occurrence, and improve the production process of master cylinder with special attention to critical defects. In order to improve this process, critical flaws had to be identified and eliminated from the entire set, which was the engineering problem to be solved. Then the causes of their occurrence as well as the factors causing process disturbances affecting the final occurrence of the defect were identified, and actions eliminating or limiting their occurrence were proposed. In the project, they were used to analyse the tools and principles, i.e. process diagram, Pareto-Lorenz diagram, cause-effect diagram, and to improve the Poka-Yoke process. Findings: Based on the examined causes of defects, improvements were proposed, i.e. guides for applying the body, a program stopping the piston assembly station to control the oil level, purchase of caps from sealed material and the need to work in long-sleeved work clothing, moving the body type verification camera from the final to first station, pallet spacers to protect against piston damage, change of supplier, especially of body castings. Research limitations/implications: The major limitation of the paper is that it is based on one case of an organization. In the future, it will be necessary to conduct studies in more organizations so as to find out if the same result can be achieved. Originality/value: Until now, no quality management tools have been used to analyse and organize the formation of defects in production processes.