Quality improvement of a product on the example of a fender for a car trailer – a case study

dr inż. Anna MAZUR – Politechnika Poznańska, ul. J. Rychlewskiego 2, 60-965 Poznań, Polska, e-mail: anna.mazur@put.poznan.pl
inż. Klaudia RAICH – Politechnika Poznańska, ul. J. Rychlewskiego 2, 60-965 Poznań, Polska
inż. Gabriela WASICKA – Politechnika Poznańska, ul. J. Rychlewskiego 2, 60-965 Poznań, Polska
inż. Weronika SOCHA – Tulplast Socha Sp. K., ul. Wiosenna 27, 62-021 Paczkowo, Polska

Received 13.05.2026. Accepted 19.05.2026

pp. 21-30

Abstract

Purpose: The purpose of the study is to present a quality improvement project for a car trailer fender using an integrated approach based on quality management tools and the Global 8D methodology.
Design/methodology/approach: The research was conducted in three stages, employing triangulation of data sources and analytical methods. The rese­arch process utilized tools such as the Ishikawa diagram, Pareto-Lorenz analysis, and relation diagram, while the conceptual and implementation phase involved a process diagram as well as Global 8D and 5S methodologies.
Findings/conclusions: It was demonstrated that the primary causes of defects were organizational factors and a lack of objective visual control. The im­plementation of the proposed corrective action plan – including a defect catalog, quality alerts, and standardized instructions and control cards – resulted in a reduction of the complaint rate for the analyzed product.
Research limitations: The article presents a case study of a single product within a specific plant, which limits the direct generalization of the results to the entire industry. It is suggested that future research be conducted to evaluate the long-term sustainability of the implemented solutions.
Practical implications: The presented solutions, such as quality alerts and the 8D report, constitute ready-to-implement best practices in proactive quality management that can be adopted by manufacturing enterprises.
Originality/value: The value of this study lies in demonstrating the synergy between traditional quality tools and the modern Global 8D methodology within the specific context of the automotive industry. The case study documents the effectiveness of proactive quality management in eliminating human errors.

Keywords

quality improvement, quality management, process standardization, Global 8D, 5S method