This thesis work has been conducted at International Automotive Components Group in Torslanda, Sweden. The company produces door panels, instrument panels, consoles and cockpits for the automotive industry.

During the production of door panels, defects such as pressure marks and scratches emerge which results in scrap and rework. The objective of the thesis work was to identify the causes of pressure marks and scratches and also to suggest measures to reduce the amount of scrap and rework on door panels.

Through observations, interviews and experiments, several causes leading to pressure marks and scratches on door panels were identified. Small pieces of plastics on fixtures, the operator's rough handling and specific process steps are the main causes that result in pressure marks and scratches.

Pressure marks and scratches emerge at several places on the door panels during the production. To reduce the amount of pressure marks and scratches both short-term and long-term measures were suggested. Some of the measures are:

•  Use vacuum cleaners at some stations
•  Add padding on unpadded areas and edges
•  Make new instructions that emphasize to keep production stations clean and to avoid rough handling
•  Introduce workshops to engage operators