Der PDCA-Zyklus als Werkzeug für die kontinuierliche Verbesserung der Qualität in der Fertigung

Abstract

In this paper, the PDCA cycle is considered as a tool for the continuous improvement of quality in manufacturing. The approach presented offers a structured framework for the systematic recognition of errors and the implementation of improvements. The present thesis examines the extent to which the complete and correct application of the cycle contributes to an improvement in complaint and rework rates. The analysis is centred on the operational processes of manufacturing companies. The results are based on an analysis of the relevant literature as well as an empirical study. The findings of this study demonstrated that the consistent execution of all phases of the PDCA cycle resulted in enhanced quality outcomes. In practice, the improvement measures implemented included process optimisations and the addition of further inspection and control steps. Identified sources of error were eliminated, and new standards were established. An exemplar of such a solution is a fixture integrated into the assembly process, which has been shown to prevent recurring errors and reduce customer complaints. The findings from both the extant literature and the expert interviews confirm that PDCA measures can contribute to improving complaint and rework rates. The implementation process is often accompanied by a number of challenges. The main reasons cited for this are the lack of time and resources in day-to-day business, and the limited capacities of managers, which make it difficult to complete the cycle in full. Further obstacles arise from the bureaucratic effort involved, including meetings, documentation, incomplete communication structures and unclear responsibilities. The consistent application is made more difficult by a lack of commitment from senior management and resistance from experienced employees. A robust management culture and explicit standards have been shown to facilitate the sustainable anchoring of the PDCA cycle. The prioritisation of continuous improvement by the company management team and its practical implementation leads to increased commitment. Standardised training and templates ensure that all employees use a common language and approach. Transparent communication about improvements and the involvement of the workforce can increase motivation. This paper concludes that when applied correctly, the PDCA cycle is an effective tool for continuous quality improvement. Systematic error analysis and elimination reduces production errors, resulting in a sustained reduction in complaint and rework rates. A well-developed culture of continuous improvement and effective error management, dedicated management, and a suitable framework are all important factors.

Date of Award	2025
Original language	German (Austria)
Supervisor	Herbert Jodlbauer (Supervisor)