QUALITY CONTROL AND PERMANENT IMPROVEMENT – OUR APPROACH TO MANUFACTURING PLASTIC COMPONENTS FOR THE AUTOMOTIVE INDUSTRY
The automotive industry sets high quality standards for the entire industry. Every component used in the production of automobiles must meet strict standards to ensure reliability and safe driving. Passive safety systems and parts that protect passengers during an accident play a special role. They must be manufactured according to strict standards and undergo demanding tests to meet the highest quality standards. In order to achieve perfect compliance of components with the specified parameters, proper production quality management is necessary. At Knauf Industries' plants located around the world, we produce a wide range of EPP and EPS foamed automotive parts. In our daily operations, we combine extensive know-how, innovation and years of processing experience with the best standards developed in the automotive industry.
WHY IS QUALITY CONTROL SO IMPORTANT IN THE AUTOMOTIVE INDUSTRY?
Automotive has a major impact on human life – cars not only allow free movement, but have even become part of the lifestyle. Their high quality influences comfort, design and – above all – driving safety. In turn, the quality of a car is closely dependent on what components it is made of, how they are fitted together and how they work together. Car manufacturers produce only a small number of car parts, the vast majority of them coming from third-party sub-suppliers. This is why the industry has developed some of the most stringent quality standards. The best example is the global automotive conglomerate Toyota, which has become the benchmark for quality standards for manufacturing companies around the world.
The restrictive standards of the automotive industry must be met by both the automotive manufacturer (OEM) and the Tier 1, Tier 2 or Tier 3 subcontractors that appear throughout the supply chain. Knauf Industries has extensive experience in each of these roles, so we are well versed in the specifics of quality requirements at all stages of the supply chain.
PERMANENT IMPROVEMENT IN PRACTICE – TYPES OF CONTROL ON THE EXAMPLE OF THE KNAUF INDUSTRIES WROCLAW PLANT
Knauf Industries' Polish plant in Wroclaw produces a full range of injection-molded components for the automotive industry, which are used both inside and outside of cars, so continuous improvement in line with the Kaizen concept is very important here.
The key is to properly identify critical processes and ensure that they are running as expected. A helpful method in this regard is statistical process control (SPC), which is used to monitor and control production processes. Potential errors and risks to product quality can be eliminated by daily internal audits on the production line.
We also use the Poka-Yoke method of quality control developed by Toyota, at the core of which is the principle of “zero defects” that could arise, for example, as a result of human inattention. The precise control is made possible by modern technologies accumulated in our own measurement laboratory. Parameters of manufactured parts are checked using laser sensors, vision cameras or spectrophotometers.
However, the most important thing is to avoid mistakes even before they are made, so we invest heavily in human capital, through training and skillful management of human resources. In fact, it is experienced production workers who create quality, and technology is only a support. Most of the Knauf Industries team are long-term employees, which gives great stability and confidence in the correct course of their processes.
QUALITY MANAGEMENT SYSTEMS AT KNAUF AUTOMOTIVE
The current pace of development in the global manufacturing environment requires constant adherence to quality and consistency in production. In the automotive industry, effective quality management is critical and affects every company in the long supply chain.
As manufacturers of injection-molded and foamed automotive parts for major automotive concerns, we consider quality a key factor in our business. Every move in the automotive industry is made with a view to continuously improving the value experienced by both current and future customers. Achieving perfect compatibility of a component with strictly defined parameters requires proper management of processes related to production quality.
Knauf Industries manufactures a wide range of automotive parts from EPP and EPS foams at 18 of our 38 plants located in different parts of the world. In our daily operations, we combine extensive know-how, innovation and years of experience in plastics processing with the best standards developed in the automotive industry. Safety, performance, comfort and design are just a few areas that are subject to continuous development and quality management in the automotive industry. It is not without reason that the requirements for inspectors and auditors, as well as those for processes and documentation in production plants, are constantly increasing – quality is becoming an increasingly high priority issue.
By obtaining and maintaining these industry-leading certifications, we are able to assure customers that our products and processes are fully compliant with international and national regulations and standards.
QUALITY MANAGEMENT SYSTEM IATF 16949
- Ensures that our processes are aimed at continuous improvement.
- Ensures that products are manufactured according to customer standards.
- Increases processing efficiency (less rejects and downtime).
- Ensures continuity of supply.
- Standardizes rapid and effective response to problems..
- Sets standards in the development and introduction of new business.
- Ensures proper competence of employees.
- Ensures the highest standard of risk management.
ISO 9001 QUALITY MANAGEMENT SYSTEM
ISO 9001 is a guarantee of continuous improvement of quality management systems (QMS) and processes at all production sites. Thanks to our certification, we are able to meet the most stringent quality requirements of our customers, guaranteed by our adherence to 7 principles:
- QMP 1 – Customer Focus: our primary goal is to meet customer requirements and strive to exceed customer expectations.
- QMP 2 – Leadership: managers at all levels provide unity of purpose and direction for the entire organization to create an environment in which all employees are committed to achieving quality goals.
- QMP 3 – Involvement of people: employees at all levels of the organization are competent, responsible and committed people focused on creating and delivering quality.
- QMP 4 – Process approach: our business is understood and managed as interrelated processes that form a coherent system. With this approach, consistent and predictable results are achieved more efficiently and effectively.
- QMP 5 – Improvement: we focus on improving performance by strengthening control processes and identifying the causes of problems, then taking preventive and corrective action. ISO 9001 ensures the ability to anticipate and respond to internal and external risks and opportunities. It also encourages innovation throughout the organization.
- QMP 6 – Evidence-based decision-making: we have an excellent understanding of cause-and-effect relationships and potential unintended consequences of our activities. Facts, evidence and data analysis ensure objectivity and confidence in decision-making.
- QMP 7 – Relationship management: optimal relationship management with our suppliers and partners is of particular importance to us. It ensures a good supply chain that provides a stable flow of goods and services and enhances our ability to create value for stakeholders by sharing resources and competencies.
ISO 14001 ENVIRONMENTAL MANAGEMENT SYSTEM
The introduction of ISO 14001 demonstrates a commitment to the environment throughout our operations. It ensures that we comply with the latest environmental regulations and reduce activities that have an adverse impact on nature on a daily basis. What are its benefits?
- Continuous compliance with environmental regulations
- Minimization of energy and resource consumption, thereby reducing operating costs
- Continuous improvement of environmental performance
XCEED – blockchain technology to certify vehicle compliance
The XCEED (eXtended Compliance End-to-End Distributed) blockchain project aims to certify the compliance of all vehicle components, from design to production. The idea behind the project is to create a compliance and customization platform for the entire ecosystem, based on IBM Blockchain technology. With XCEED, we can improve our quality, reduce costs and waste, and anticipate problems. XCEED increases transparency and trust within the ecosystem, but this trust and confidence is also gained by our customers.
Knauf – high quality and reliability in the production of plastic parts for the automotive sector
Knauf Industries is synonymous with the highest quality and reliability in the production of plastic components for the automotive industry. Through rigorous standards and continuous improvement, we are able to meet and exceed our customers' expectations. We invite you to contact us to learn how our advanced solutions can support your projects. Fill out the form and see how we can help you achieve your goals.