Transport Defect Reduction in Ceramic Stove Distribution using Integrated 7QC Tools and Modified FMEA

Abstract

This study aims to develop and validate an integrated transport-phase quality management framework for reducing transportation defects in fragile ceramic products produced by community enterprises. A case study was conducted at the Ban Chat Community Enterprise Group in Roi Et Province, Thailand. Baseline data collected between April and August 2025 showed an average transport defect rate of 10.35%, exceeding the enterprise acceptance threshold of 5%. Pareto analysis identified Pot Rest Fracture (39.16%) and Base Fracture (30.62%) as the dominant defect categories. Root causes were systematically identified using the 4M1E Fishbone Diagram and verified through Why-Why Analysis, while a Modified Risk Priority Number (MRPN) model incorporating a Controllability factor was applied to prioritize corrective actions according to both risk severity and implementation feasibility. The analysis identified inadequate EVA foam cushioning and the absence of standardized operator training and loading procedures as the two highest-priority root causes. Corrective actions consisted of replacing EVA foam with expanded polyethylene (EPE) cushioning and implementing a 90-minute standardized training programme covering safe handling, stove arrangement, foam placement, and standard operating procedures. Post-intervention monitoring from October 2025 to March 2026 reduced the average defect rate to 3.80%, representing a 63.24% reduction from baseline, while maintaining defect levels below the 5% acceptance threshold throughout the evaluation period. The study demonstrates that integrating 7QC Tools, the 4M1E taxonomy, Why-Why Analysis, and feasibility-adjusted MRPN provides an effective and practical approach for transport quality improvement. The proposed framework offers a transferable decision-support model for reducing transportation defects in resource-constrained community enterprises handling fragile products.