Identification and improvement of processes using selected quality tools: a case study

The aim of this work was to determine the effectiveness of using the FMEA method in the traditional and modern versions for a small company producing plastic toys. It also identified the production process of a plastic instrument toy selected for analysis by dividing operations into adding and not adding value, in accordance with the Lean concept. Through the FMEA sheets constructed and presented in this work in both versions of this method, the causes and effects of defects in the technological operations of the production process of the test subject were presented. A risk analysis was carried out using assessments available for the traditional and new versions, and preventive and detective actions were proposed. The result of the work was a comparison of risk indicators characteristic for both versions of the FMEA method and an assessment of the effectiveness of this method in the analysed enterprise. Emphasis was placed on the human factor in the research. Both the division of operations into adding and not adding value, as well as the FMEA method, were useful for further optimization and process improvement activities.