An analysis of factors leading to the production of defective wagons in Transnet Engineering

Abstract

Rail manufacturing industries play a crucial role in many countries by developing cost-effective transportation solutions to move freight more efficiently. To date, the industry has seen the implementation of traditional quality management practices that are critical in driving efficiencies and better-managed operations to improve the quality of their freight wagons. Despite the conventional quality management techniques, the rail industry continues to manufacture defective rolling stock due to design changes, errors and omissions, and inadequate skills. Over the past few decades, industry and academia have identified various factors contributing to rolling stock manufacturing defects. Nevertheless, which factors were predominantly responsible for the defective wagon production at the Transnet Engineering (TE) Bloemfontein factory remained unclear. Identifying the most prevalent causes of defects is essential in addressing the organisation's quality issues. The primary purpose of this study was to gain insights into the root causes of the defects and recommend strategies to minimise them. The study used an interpretive methodology to identify the root cause of defective wagons produced at TE. Data was collected using purposive sampling. Ten experienced TE employees actively engaged in freight wagon manufacturing were selected for face-to-face interviews. During the research study, the interviews were conducted with the employees using a semi-structured format that allowed for open-ended questions. Investigative techniques, such as cause-and-effect diagrams and the Five "Whys" root cause analysis tool, were used to investigate defects' root causes on the customer complaints register. Additionally, thematic analysis was applied to thoroughly analyse the interviews conducted with the employees, which allowed for a deeper understanding of the issues at hand. The findings showed that inadequate skills, human errors and omissions, a lack of quality culture, time constraints, management's failure to enforce accountability, and poor workshop maintenance/machinery all contribute to defective wagon production. The research provided recommendations, including adopting innovative technology and skills transfer programs to enhance the company's quality management practices.