Continuous quality improvements are essential to any company’s success strategy. However, achieving this goal can be challenging when dealing with complex products and processes. RELINE has embraced its own Total Quality Management (TQM) system to address this challenge, and its commitment has yielded impressive results. The 2024 TQM Quality Report for the GRP pipe liner manufacturer has recorded new performance milestones.
Between 2022 and 2024, the quality rate of delivered products improved fivefold.
“Without our TQM system, such progress would not be possible,” says Philipp Martin, Director of Sales & Marketing. “The management system enables comprehensive monitoring by recording every process in a centralized database from goods receipt and production steps to material testing and user feedback,” adds Stefan Reichel, Head of Quality & Technology. By analyzing data from more than 9,000,000 meters of Alphaliner produced, the RELINE team continuously identifies opportunities for optimization.
Measures driving sustainable quality improvements
The positive trends highlighted in the latest TQM report result from a combination of strategic measures:
- Enhancing the Inner Film Process (2022): RELINE focused on optimizing the inner film required for installing UV-curing Alphaliner.
- Adjustments in incoming goods inspection, storage, and the loading process significantly reduced complaints related to production.
- Manufacturing Process Optimisation: Targeted modifications ensured consistency in composite thickness. Standardized production parameters, newly established quality limits for in-situ thickness measurements, and quality checkpoints prevent deviations. A 100% weight control system further guarantees accuracy before delivery.
Employees: The core of TQM success
While technical optimizations are crucial, RELINE recognizes that employee involvement is equally important. A process-oriented approach makes production workflows transparent and accessible for all team members.
- Standardised workflows: Individual work steps are clearly defined and visually illustrated for easy understanding. Regular training ensures employees adhere to best practices, and process improvements are made as needed.
- Open communication culture: RELINE fosters an environment where employees can openly discuss anomalies and actively participate in problem-solving. Daily shop floor meetings and regular Gemba walks reinforce this commitment by addressing safety, compliance, and lean management principles like the 5S method.
Interface management: Precision in communication, seamless execution
RELINE takes a proactive approach to communication, ensuring smooth coordination across the entire value chain.
“Critical data and process results must be precisely aligned to avoid complications,” explains Stefan Reichel. “At key interfaces, we prioritize structured exchanges to minimize delays and optimise downstream processes.”
A prime example is Alphaliner’s delivery planning. Effective coordination through TQM has led to an impressive 99.6% on-time delivery rate in 2024, enabling seamless execution of sewer rehabilitation projects.
Waste reduction: Advancing sustainability goals
Sustainability remains a priority. While GRP pipe liner repairs are significantly more environmentally friendly than traditional methods, their production involves synthetic materials. Responsible resource management is crucial.
From 2022 to 2024, RELINE successfully reduced its waste rate by over 10%. However, this is just the beginning. The team is committed to further minimizing production waste and improving material separation for recycling.
The future of quality at RELINE
Through its Total Quality Management system, RELINE continues to push the boundaries of quality, efficiency, and sustainability. Step by step, the company is shaping a future where structured processes drive superior outcomes—for customers, employees, and the environment alike.
