Risk Assessment and Analysis in Toy Production: A Case Study of Plastic Block Manufacturing Using Pareto-Lorenz and FMEA Methods

Abstract This paper presents a comprehensive risk assessment and analysis in the production of plastic toys - specifically building blocks - conducted using the Pareto-Lorenz diagram and the Failure Mode and Effects Analysis (FMEA) method. The study addresses the challenges faced by toy manufacturers, particularly in the small and medium-sized enterprise (SME) sector, in meeting stringent safety and quality requirements for children’s toys. The Pareto-Lorenz diagram identified the most frequent nonconformities in the production process, revealing that small protruding parts and sharp edges accounted for 71.65% of all detected defects. The FMEA method, applied in a novel approach, allowed for the prioritization of risks and the identification of key areas for improvement, such as material selection, injection molding parameters, and quality control processes. Based on the findings, the study proposes targeted optimization measures to enhance product quality, safety, and production efficiency. These results contribute to the body of knowledge on risk management in toy manufacturing and offer practical solutions for improving compliance with industry standards.