Application of the 4M Framework in Reducing Defect Rates: A Case Study from Thailand's Plastic Mats Manufacturing Sector

Abstract

This study examines the impact of four key production factors - Manpower, Machine, Material, and Method (4M) on defect rates in the plastic mat manufacturing process. Conducted at a plastic mat factory in Khon Kaen province, Northeastern Thailand, the research employed a quantitative approach with data collected from 100 operational staff through structured questionnaires. Descriptive statistics and multiple regression analysis were used to analyze the data at a 0.05 significance level.

The findings indicate that Manpower, Material, and Method significantly affect defect rates, while Machine does not show a statistically significant influence. Among the significant predictors, Material has the greatest impact, followed by Manpower and Method. The results underscore the critical role of skilled labor, consistent raw material quality, and clearly defined production procedures in minimizing defects and improving production efficiency. The study provides practical insights for manufacturers aiming to enhance product quality and operational performance through systematic quality management and workforce development.