Robust Design Methodologies for Perceived Quality Improvement: A Case Study on Door to Body Gaps and Flush in Automotive Production

This master’s thesis is the result of a collaboration between the Motor Valley University of Emilia-Romagna and the Quality Department of Maserati, at the Modena plant, which is the production site for the MCPURA, GT2 Stradale, Granturismo, and Grancabrio models. The curricular internship, which is the subject of this thesis, was aimed at acquiring and applying engineering skills within the luxury automotive industry. The premium luxury vehicle sector represents a multibillion-dollar segment of the global economy, characterized by an estimated annual growth rate of 10%. These vehicles integrate stringent safety standards, advanced engineering solutions, and continuous innovation processes, making quality management an essential element both in the development of production processes and in product realization. This thesis focuses on quality management and containment actions adopted within the framework of a case study conducted during the internship at the Maserati brand. The analysis begins with an understanding of the company’s product portfolio, the differences among the models and production processes, as well as the quality standards applied throughout the entire value chain. Quality plays a critical role due to its direct correlation with end-user safety. Furthermore, maintaining high quality standards contributes to strengthening brand reputation, increasing customer satisfaction and loyalty, improving product reliability, reducing resource waste, and optimizing overall operational efficiency. In the context of luxury vehicles, quality is defined by excellence in design, engineering, materials, and customer experience, and must be ensured throughout the entire vehicle life cycle. In this thesis project, attention was focused on the manufacturing process of the four models, evaluating the variability of gap and flush values across the four models throughout the vehicle production phases. These parameters are fundamental in the realization of luxury vehicles, both for functional and aesthetic purposes. During the internship period, anomalies were analyzed and a systematic and structured approach was adopted to identify the root cause. This approach led to the proposal of corrective measures that will modify the production flow starting from the first quarter of 2026, further enhancing the quality of the models produced at the Modena plant.