Industry 4.0 technologies applied to nonconformity management: an empirical study of Brazilian manufacturing firms with certified quality systems

Abstract

Purpose This study investigates the deployment of quality tools and Industry 4.0 (I4.0) technologies within the nonconformity management (NCM) processes of Brazilian manufacturing companies with certified quality system.

Design/methodology/approach Employing a sequential mixed-methods design, the research began with a systematic literature review (SLR) to delineate the landscape of I4.0 technologies relevant to NCM. Subsequently, a descriptive and exploratory survey was conducted with 112 industrial companies. The survey collected data on established NCM practices, the degree of I4.0 technology integration and perceived barriers to implementation. Quantitative data were analyzed using cluster analysis and association tests.

Findings The SLR highlighted a theoretical emphasis on the application of big data and machine learning across NCM stages. However, empirical results revealed that while most companies have formalized NCM procedures, the adoption of I4.0 technologies most widely adopted are cloud computing and system integration. Companies with higher intensity in using traditional quality tools, key performance indicators and information technology support reported significantly greater perceived NCM effectiveness.

Practical implications The findings indicate that integrating traditional quality management tools with intelligent I4.0 technologies can significantly enhance NCM performance, provided that cultural and leadership barriers are effectively addressed. This study offers practical guidance for quality management professionals aiming to modernize NCM processes and align them with the broader goals of digital transformation.

Originality/value This study contributes to the evolving knowledge base by synthesizing literature on I4.0 applications in NCM and providing original empirical evidence concerning the current state of their implementation within certified Brazilian manufacturing settings.