Abstract
Defect reduction is a constant challenge for quality improvement in any organisation. The research was a case study in a small firm performing chroming process for variety of plastic end-cups. The chroming process uses combination of paint spraying and metalising. To improve their quality assurance process, the study assisted in identifying major failure modes and their root causes using fault tree analysis. It was then continued with failure mode and effect analysis for quantifying risk priority for each failure modes. The results recommended the studied company to focus on failure mode 'uneven spraying', 'incorrect setting of paint output', 'incorrect setting of spray pressure', 'dusty production area', and 'dusty oven', and suggested some control improvements against them.
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