This paper presents the application of the 8D method to a case study in the automotive industry, combined with the development of a pilot framework that integrates Industry 4.0 technologies—Artificial Intelligence (AI), Internet of Things (IoT), and advanced IT tools. Unlike traditional 8D implementations, the proposed solution introduces several innovations: (i) AI-based complaint analysis with automated keyword detection and classification and localization of batches in the warehouses achieving a 100% accuracy rate in categorizing root causes; (ii) IoT-enabled non-invasive monitoring of production parameters for tests and logs, reducing fault rate to 0 for current case study; (iii) digital cataloging and storage of corrective and preventive actions, improving retrieval speed of past solutions by 300 times (from 300 min to less than 1 min); and (iv) automated reporting tools, cutting the report preparation time from hours to minutes. Through these contributions, the system enhances both responsiveness and prevention, leading to an observed 100% reduction in fault recurrence associated with current case study and an estimated 75% decrease in customer complaints regarding defects occurring throughout the production sector where the pilot was implemented. In addition to the practical improvements, this work extends the literature on digitalized quality management by demonstrating how the 8D methodology can be effectively re-engineered with Industry 4.0 components. Comparative analysis against the enterprise’s conventional 8D system and against recent alternative approaches confirms that our framework provides measurable benefits in the speed, accuracy, and sustainability of problem-solving processes.

The ever-increasing needs of the working population have led to the development of various branches of industry, an increase in the number of employees, and a rise in the number of work-related accidents. The welder occupation is one of the most sought after occupations in Europe, according to the EURopean Employment Services (EURES) statistics. Taking into account the work system in which welders conduct their activity (uncomfortable working positions, splashes, high temperatures, mechanical factors, gases and fumes, magnetic fields due to electric current), the paper presents the risk factors identified for the welder occupation, based on the occupational injury and illness risk assessments. Following the analysis of 25 risk assessments, carried out by the assessment team that must include qualified evaluators, process specialists, the workers’ representative, occupational health and safety responsible at various industrial economic agents, a total of 70 main risk factors of occupational accidents and diseases were identified for the welder occupation. Risk factors were classified according to four main work components: worker, workload, work environment, and means of production. To reflect the importance of the identified risk factor, the number of organizations that considered that the risk was likely to occur but also the possibility that the risk was above the acceptable limit, calculated using the National Institute for Research and Development for Labor Protection “Alexandru Darabont” (INCDPM) method, a method often used in Romania, was identified from the analyzed assessments. Finally, a prevention and protection plan was drawn up with regard to the risks identified for the welder occupation, the final aim of which was to respectively reduce the probability of occurrence with the severity of the risks identified.

The implementation of a management system has increasingly become a necessity for organizations, one of the main purposes being to establish actions to achieve quality objectives. Currently there are many management systems but for a manufacturer of welded structures, in addition to the quality management system according to EN ISO 9001:2015 it is recommended to implement EN ISO 3834-2:2021 “Quality requirements for fusion welding of metallic materials. Part 2: Comprehensive quality requirements” The paper presents applied research on the assessment of the management system of a welded structure manufacturing organisation by conducting two internal audits at 7-month intervals as well as the analysis of the evolution of the management system after the implementation of corrective measures established after the first audit performed.