Title: Manufacturing quality of a vehicle occupant protection module: a case study approach

Authors: António Rocha; Bruna Miranda; Eduarda Teixeira; Henrique Sousa; Márcia Araújo; Raissa Castro

Addresses: Polytechnic Institute of Cávado and Ave, School of Technology, 2Ai – Applied Artificial Intelligence Laboratory, Portugal ' Polytechnic Institute of Cávado and Ave, School of Technology, Portugal ' Polytechnic Institute of Cávado and Ave, School of Technology, Portugal ' Polytechnic Institute of Cávado and Ave, School of Technology, Portugal ' Polytechnic Institute of Cávado and Ave, School of Technology, Portugal ' Polytechnic Institute of Cávado and Ave, School of Technology, Portugal

Abstract: This study examines two manufacturing processes used for producing vehicle occupant protection modules. Case study 1 analyses deviations affecting the 'claxon' function, while Case study 2 compares data from two assembly lines producing the same product but equipped with machinery from different suppliers. Five research questions are addressed to evaluate quality factors. Q1 explores customer expectations' impact on quality, followed by Q2 examining the relationship between customer satisfaction and product quality. Q3 analyses the effect of machine maintenance, while Q4 investigates the impact of identifying deviation causes. Lastly, Q5 explores the relationship between design choices and product quality. Through detailed analyses and addressing these questions, this study aims to provide insights into the relationship between manufacturing processes, customer expectations, design, and quality. The findings will enhance understanding, enabling informed decisions and strategies to improve product quality and customer satisfaction in manufacturing vehicle occupant protection modules.

Keywords: manufacturing quality; quality control; capability analysis; compliancy.

DOI: 10.1504/IJPQM.2025.146633

International Journal of Productivity and Quality Management, 2025 Vol.45 No.2, pp.187 - 211

Received: 10 Jul 2023
Accepted: 14 Jul 2023
Published online: 10 Jun 2025 *

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