Integrated framework for failure identification and prevention in molding of thermoplastic polyvlies composites – case study

• An integrated framework combines FMEA, TPM, and lean approaches in composite molding. • A simulation model validates failures and prevention in the real Polyvlies process. • Most failures result from improper handling and noncompliance with temperature limits. • Robotic manipulation increased production throughput by 7.71% • The proposed approach reduces failure rates, downtime, and operator physical load. This case study presents an integrated framework for identifying and preventing failures in the molding process of thermoplastic composites with a focus on Polyvlies material. This hybrid composite, consisting of 50% natural and 50% polypropylene fibers, is characterized by a low density (approximately 0.7 g/cm 3 ), high specific strength, and significant sensitivity to temperature and pressure. The proposed approach combines elements of FMEA, TPM, and lean analytical procedures and is supported by a detailed simulation model of the production process. Research on a real example identifies key handling-temperature failure mechanisms when inserting a semi-finished product made of Polyvlies material into a technological device, which result in the creation of a non-conforming product (failure), damage to shear edges, the creation of dimensional deviations, tolerance deviations and undesirable process states in the form of downtime, production interruptions, reduced stability and efficiency of the technological process. These failures result from incomplete consolidation or thermal degradation of the thermoplastic composite material Polyvlies when critical process parameters are not met. The scientific contribution of the work is the demonstration of a direct dependence of process stability on the time spent manipulating the preheated semi-finished product, with a limit of 30–40 s to eliminate heat losses that lead to macrostructural defects. Using the proposed integrated framework and implementing the robotic system based on it, verified through simulation experiments, it was demonstrated that the forming press error rate was reduced from 16% to 4%, and the production throughput increased by 7.71%. In addition to increasing efficiency, the operator’s distance traveled was reduced by 14.62%, confirming a positive impact on workplace safety and ergonomics. The results confirm that the combination of systematic failure analysis and simulation modeling represents an effective tool for optimizing production and supporting decision-making in the processing of thermoplastic Polyvlies composites.