Quality Analysis and Improvement of Protective Body Covers used in Premium Vehicle Logistics

The premium luxury vehicle industry represents a multi-billion-dollar segment of the global economy, with a projected annual growth rate of 10%. These vehicles incorporate critical safety standards, advanced engineering, and continuous innovation, making quality management an essential aspect of both process and product development. This thesis focuses on quality management and the containment actions taken during a specific case study conducted during my internship with a premium vehicle manufacturer. The study begins by understanding the brand’s product portfolio, differences between the products, and the production processes and quality standards applied throughout the value chain. Quality is primarily critical due to its direct connection to human safety. Additionally, maintaining high-quality standards contributes to enhanced brand reputation, increased customer satisfaction and loyalty, improved product reliability, reduced resource wastage, and overall operational efficiency. In the context of luxury vehicles, quality is defined by exceptional standards in design, engineering, materials, and customer experience, and must be maintained across the entire vehicle lifecycle. For this thesis, the quality performance is focused on post-production processes. Specifically, defects reported by dealers prior to customer delivery were analysed, with a particular emphasis on aesthetic concerns such as paint quality. The objective is to ensure zero-defect delivery by monitoring and improving performance across production, logistics, and dealer operations. The case study addresses issues identified during the logistics phase, especially during the transportation of vehicles from the company to overseas dealers. These issues were analysed using company-defined quality tools and methodologies. Corrective measures were implemented, and their effectiveness was verified through testing of subsequent production batches, ensuring that defects did not reach the dealer and the end customer. A systematic and time-bound approach was employed to identify root causes, implement solutions, and prevent recurrence. This thesis contributes to the broader goal of continuous quality improvement in premium automotive logistics, reinforcing the importance of robust quality control in maintaining product integrity and ensuring customer satisfaction.