Multivariate Nonconformity Analysis for Paving Stone Manufacturing Process Improvement

Abstract The article presents the result of multidimensional analysis of ‘Behaton’ type paving stones’ nonconformities for improving the production process by improving the quality of the final product. Statistical tools, including SPC tools and quality tools, both basic and new, were used to analyse nonconformities in the spatial-temporal system, i.e. according to the type of nonconformity and according to the examined months. The purpose of using the data analysis tools was to thoroughly analyse the cases of nonconformities of the tested product, obtain information on the structure of these nonconformities in the various terms, and information on the stability and predictability of the numerical structure of nonconformity over time. Potential causes influencing a large percentage of paving stone defects were identified, factors and variables influencing the most frequently occurring nonconformities were determined, and improvement actions were proposed. As a result of the multidimensional and multifaceted analyses of paving stone nonconformities, it was shown that in the structure of nonconformity there were cases that were unusual in terms of the number of occurrences, and the lack of stability in the number of nonconformities in terms of the examined months was proven. Three critical nonconformities of the tested product were identified: side surface defects, vertical edge defects, and scratches and cracks. It was determined that the most important factor causing a large percentage of nonconformity was the time of shaking and vibrating the concrete, which was significantly related to the technical condition of the machines, and the most important reason for a large percentage of paving stone nonconformity was the lack of efficient maintenance. Machine, method, and man turned out to be the most important categories of problem factors and specific remedial actions were proposed. A multidimensional look at the structure of paving stone nonconformity as well as the factor and causes causing them has brought a lot of valuable information for the management staff of the analysed company, thanks to which it is possible to improve the production process and improve the quality of the final product.