Quality improvement in bottle production: a case study on FMEA and Pareto-Lorenz methodologies

The increasing demands for product quality and production efficiency in the plastics industry necessitate the use of structured quality management tools. This study aims to identify critical defects in the production of water bottles using the Pareto-Lorenz analysis and Failure Mode and Effect Analysis (FMEA). The research was conducted in a company specializing in bottle manufacturing, where production incon sistencies were analyzed based on quality control reports. The Pareto-Lorenz method revealed that the majority of defects were attributed to issues related to material injection and assembly oversight. The FMEA analysis prioritized defects based on their severity, occurrence proba bility, and detection difficulty, assigning Risk Priority Numbers (RPN) to facilitate targeted corrective actions. Implemented solutions, such as enhanced quality control procedures and systematic employee training, resulted in a significant reduction in defect occurrence and improved production efficiency. The study confirms that combining FMEA and Pareto-Lorenz analysis is an effective approach for optimizing quality management in industrial settings, offering practical insights for manufacturers seeking to enhance product reliability and competitiveness.

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Opracowanie rekordu ze środków MNiSW, umowa nr POPUL/SP/0154/2024/02 w ramach programu "Społeczna odpowiedzialność nauki II" - moduł: Popularyzacja nauki (2025).