Integrating the I–S Model and FMEA for Process Optimization in Packaging and Printing Industry
Abstract
1. Introduction
- To identify the key manufacturing factors in the paper packaging design industry through literature review and in-depth interviews.
- To determine the priority of improvement items in the case study using the Importance–Satisfaction Model (I–S Model) and Failure Mode and Effects Analysis (FMEA).
- To propose specific recommendations based on the findings, thereby offering managerial and operational insights for the paper packaging design industry.
2. Literature Review
2.1. Overview of the Packaging Design Industry
- ➢
- Early development: Initially, printing processes were primarily manual and served mainly the production of books and newspapers. With gradual technological progress, the industry transitioned toward mechanized and automated systems.
- ➢
- Technological advancements: The evolution from traditional letterpress printing to modern digital technologies has substantially improved production efficiency, print precision, and cost-effectiveness. Each wave of innovation has contributed to higher productivity and better-quality control.
- ➢
- Environmental considerations: In response to growing awareness of environmental sustainability, numerous packaging and printing enterprises have adopted eco-friendly printing methods, including the use of recyclable materials and green production technologies.
- ➢
- Future trends: The future trajectory of the industry is anticipated to focus increasingly on personalization and customization, in alignment with evolving consumer preferences for distinctive and individualized products.
- ➢
- Taiwan’s global position: Taiwan occupies a competitive position in the global packaging and printing sector, driven by its advanced printing technologies, innovative design capabilities, and distinctive cultural esthetics that have garnered international recognition.
- ➢
- Clarifying product attributes: The initial step in packaging design involves a comprehensive examination of the product to delineate its core characteristics and functional purpose.
- ➢
- Identifying target users: Understanding the demographic and psychographic profiles of end users is essential for achieving an optimal balance between functionality and esthetic appeal.
- ➢
- Selecting appropriate materials: Material selection critically influences not only visual and tactile qualities but also durability, sustainability, and recyclability.
- ➢
- Considering production costs: As packaging directly affects overall production expenditure, cost assessment should be integrated into the early stages of design planning.
- ➢
- Ensuring production compatibility: The selected packaging materials and design specifications must align with existing manufacturing systems to ensure operational efficiency and minimize labor intensity.
- ➢
- Adopting sustainable design principles: Increasing global emphasis on environmental responsibility necessitates the adoption of green packaging materials and low-impact production methods consistent with circular economy principles.
- ➢
- Developing creative design concepts: After fundamental parameters are established, creative exploration and stylistic development can further enhance distinctiveness and cultural resonance.
- ➢
- Evaluating manufacturing partners: Upon completion of the design phase, selecting qualified and technically compatible manufacturers becomes critical, as complex or large-scale projects often require specialized expertise.
2.2. Importance–Satisfaction Model (I–S Model)
- ➢
- Quadrant I: Excellent Area—This quadrant represents attributes characterized by high importance and high satisfaction. Customer requirements in this category are both critical and well-fulfilled, indicating that current performance effectively meets expectations. These attributes should be continuously maintained and periodically reviewed to ensure sustained excellence and competitiveness.
- ➢
- Quadrant II: Improvement Area—This quadrant comprises attributes of high importance but low satisfaction. Customer requirements in this area are essential to customers; however, their current performance fails to meet expectations. Immediate attention and resource allocation are required to enhance these attributes, as improvements here have the greatest potential to increase overall customer satisfaction and loyalty.
- ➢
- Quadrant III: Surplus Area—Attributes in this quadrant demonstrate low importance but high satisfaction. Although customers express satisfaction with these requirements, they are not considered crucial to the purchase decision or overall service perception. Hence, if resource constraints exist, investment in these areas may be reduced without significantly affecting customer satisfaction.
- ➢
- Quadrant IV: Care-free Area—This quadrant includes attributes with both low importance and low satisfaction. Since these requirements are neither valued by customers nor contribute meaningfully to perceived service quality, they may be deprioritized or even omitted from improvement initiatives to optimize resource utilization.
2.3. Failure Mode and Effects Analysis (FMEA)
- ➢
- Pinpoint critical service or product attributes that significantly influence customer satisfaction.
- ➢
- Assess potential failure modes, their causes, and impacts on performance.
- ➢
- Prioritize improvement actions based on both customer importance–satisfaction gaps and risk levels indicated by RPN values.
- ➢
- Allocate resources efficiently to address high-priority issues, thereby enhancing product quality, customer satisfaction, and overall competitiveness.
3. Methodology
3.1. Questionnaire Design
- Pre-purchase importance survey
- 2.
- Post-service satisfaction survey
3.2. Research Participants and Sampling
4. Empirical Analysis
4.1. Descriptive Analysis of Demographic Data
4.2. Descriptive Analysis of Product Attribute Importance and Satisfaction
4.3. Implementation of the Importance–Satisfaction (I–S) Model
- ➢
- No. 2 Product design
- ➢
- No. 4 Product appearance
- ➢
- No. 5 Product quality
- ➢
- No. 7 Product durability/load-bearing capacity
- ➢
- No. 10 Employees’ service attitude
- ➢
- No. 13 Punctuality of delivery
- ➢
- No. 14 Convenience of payment
- ➢
- No. 1 Product price
- ➢
- No. 15 Vendor’s emergency response capability
- ➢
- No. 16 Flexibility in adjusting to customer needs
- ➢
- No. 18 Proactive notification of raw material price fluctuations
- ➢
- No. 6 Product Material
- ➢
- No. 11 Company Reputation
- ➢
- No. 12 After-sales Service
- ➢
- No. 3 Product functionality
- ➢
- No. 8 Product compliance with energy-saving and carbon-reduction standards
- ➢
- No. 9 Product compliance with environmental awareness
- ➢
- No. 17 Professionalism of sales staff
- ➢
- No. 19 Proactive communication of market trends by sales staff
4.4. Application of the FMEA Method
- Product price
- Flexibility in adjusting to customer needs
- Vendor’s emergency response capability
- Proactive notification of raw material price fluctuations
4.5. Discussion
- Product price
- 2.
- Flexibility in adjusting to customer needs
- 3.
- Vendor’s emergency response capability
- 4.
- Proactive notification of raw material price fluctuations
5. Conclusions and Suggestions
5.1. Conclusions
5.2. Research Limitations and Suggestions
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
Appendix A
Gender: □Man □Woman Marital Status: □Single □Married Age: □Below 30 □31~40 □41~50 □51~60 □above 60 Education Level: □Below High school □University/College □Above Master Occupation: □Public sector □Service industry □High-tech industry □Catering industry □Other | |||||
| Very Unimportant 1 | 2 | Neutral 3 | 4 | Very Important 5 |
Product price | □ | □ | □ | □ | □ |
Product design | □ | □ | □ | □ | □ |
Product practicality | □ | □ | □ | □ | □ |
Product appearance (color, innovativeness, and recognizability) | □ | □ | □ | □ | □ |
Product quality (satisfaction, safety, and reliability) | □ | □ | □ | □ | □ |
Product material | □ | □ | □ | □ | □ |
Product durability and load-bearing capacity (impact resistance and durability) | □ | □ | □ | □ | □ |
Product design aligns with ESG principles. | □ | □ | □ | □ | □ |
The product reflects environmental awareness (e.g., packaging reduction and reusability) | □ | □ | □ | □ | □ |
Employees’ service attitude | □ | □ | □ | □ | □ |
Company reputation | □ | □ | □ | □ | □ |
Company’s after-sales service | □ | □ | □ | □ | □ |
Punctuality of delivery | □ | □ | □ | □ | □ |
Convenience of payment | □ | □ | □ | □ | □ |
Vendor’s emergency response capability | □ | □ | □ | □ | □ |
Flexibility in adjusting to customer needs | □ | □ | □ | □ | □ |
Professionalism of sales staff | □ | □ | □ | □ | □ |
Proactive notification of raw material price fluctuations | □ | □ | □ | □ | □ |
Proactive communication of market trends by sales staff | □ | □ | □ | □ | □ |
| Very Dissatisfied 1 | 2 | Neutral 3 | 4 | Very Satisfied 5 |
Product price | □ | □ | □ | □ | □ |
Product design | □ | □ | □ | □ | □ |
Product practicality | □ | □ | □ | □ | □ |
Product appearance (color, innovativeness, and recognizability) | □ | □ | □ | □ | □ |
Product quality (satisfaction, safety, and reliability) | □ | □ | □ | □ | □ |
Product material | □ | □ | □ | □ | □ |
Product durability and load-bearing capacity (impact resistance and durability) | □ | □ | □ | □ | □ |
Product design aligns with ESG principles. | □ | □ | □ | □ | □ |
The product reflects environmental awareness (e.g., packaging reduction and reusability) | □ | □ | □ | □ | □ |
Employees’ service attitude | □ | □ | □ | □ | □ |
Company reputation | □ | □ | □ | □ | □ |
Company’s after-sales service | □ | □ | □ | □ | □ |
Punctuality of delivery | □ | □ | □ | □ | □ |
Convenience of payment | □ | □ | □ | □ | □ |
Vendor’s emergency response capability | □ | □ | □ | □ | □ |
Flexibility in adjusting to customer needs | □ | □ | □ | □ | □ |
Professionalism of sales staff | □ | □ | □ | □ | □ |
Proactive notification of raw material price fluctuations | □ | □ | □ | □ | □ |
Proactive communication of market trends by sales staff | □ | □ | □ | □ | □ |
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O | S | D | RPN | r |
---|---|---|---|---|
1 | 1 | 1 | 1 ≤ RPN ≤ 100 | 0.1 |
2 | 2 | 2 | 101 ≤ RPN ≤ 200 | 0.2 |
3 | 3 | 3 | 201 ≤ RPN ≤ 300 | 0.3 |
4 | 4 | 4 | 301 ≤ RPN ≤ 400 | 0.4 |
5 | 5 | 5 | 401 ≤ RPN ≤ 500 | 0.5 |
6 | 6 | 6 | 501 ≤ RPN ≤ 600 | 0.6 |
7 | 7 | 7 | 601 ≤ RPN ≤ 700 | 0.7 |
8 | 8 | 8 | 701 ≤ RPN ≤ 800 | 0.8 |
9 | 9 | 9 | 801 ≤ RPN ≤ 900 | 0.9 |
10 | 10 | 10 | 901 ≤ RPN ≤ 1000 | 1.0 |
Demographic | Items | Frequency | Percentage |
---|---|---|---|
Gender | Man | 66 | 38.37 |
Woman | 106 | 61.63 | |
Marital status | Single | 42 | 24.42 |
Married | 130 | 75.58 | |
Age | Below 30 | 18 | 10.47 |
31~40 | 23 | 13.37 | |
41~50 | 32 | 18.60 | |
51~60 | 62 | 36.05 | |
Above 60 | 37 | 21.51 | |
Education | Below High school | 41 | 23.84 |
University/College | 83 | 48.26 | |
Above Master | 48 | 27.91 | |
Occupation | Public sector | 21 | 12.21 |
Service industry | 66 | 38.37 | |
High-tech industry | 27 | 15.70 | |
Catering industry | 39 | 22.67 | |
Other | 19 | 11.05 |
Items | Importance | Satisfaction |
---|---|---|
| 4.77 | 3.86 |
| 4.49 | 4.39 |
| 4.31 | 4.11 |
| 4.34 | 4.37 |
| 4.49 | 4.32 |
| 4.07 | 4.35 |
| 4.38 | 4.27 |
| 4.15 | 3.99 |
| 4.08 | 3.82 |
| 4.42 | 4.37 |
| 4.09 | 4.44 |
| 4.15 | 4.69 |
| 4.38 | 4.59 |
| 4.33 | 4.32 |
| 4.59 | 4.25 |
| 4.61 | 4.08 |
| 4.22 | 4.08 |
| 4.69 | 3.85 |
| 3.97 | 4.06 |
Average | 4.34 | 4.22 |
No | Items | I | F | E | RPN | Ranking |
---|---|---|---|---|---|---|
No 1 | Product price | 8.66 | 7.33 | 8 | 507 | 1 |
No 16 | Flexibility in adjusting to customer needs | 7.66 | 6 | 7 | 322 | 2 |
No 15 | Vendor’s emergency response capability | 6.66 | 5.66 | 6.33 | 239 | 3 |
No 18 | Proactive notification of raw material price fluctuations | 6 | 4.66 | 5 | 140 | 4 |
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Chen, S.-H.; Yan, H.-I. Integrating the I–S Model and FMEA for Process Optimization in Packaging and Printing Industry. Processes 2025, 13, 3323. https://doi.org/10.3390/pr13103323
Chen S-H, Yan H-I. Integrating the I–S Model and FMEA for Process Optimization in Packaging and Printing Industry. Processes. 2025; 13(10):3323. https://doi.org/10.3390/pr13103323
Chicago/Turabian StyleChen, Shun-Hsing, and Huay-In Yan. 2025. "Integrating the I–S Model and FMEA for Process Optimization in Packaging and Printing Industry" Processes 13, no. 10: 3323. https://doi.org/10.3390/pr13103323
APA StyleChen, S.-H., & Yan, H.-I. (2025). Integrating the I–S Model and FMEA for Process Optimization in Packaging and Printing Industry. Processes, 13(10), 3323. https://doi.org/10.3390/pr13103323