Identification and Minimization of Risks in the Logistics Processes of a Window Blinds Manufacturing Company Using PHA and TPM
Purpose: The purpose of this study is to identify and evaluate risks in the logistics processes of a window blind manufacturing enterprise and to propose improvement measures to minimise their impact. The research focuses on internal and external determinants affecting logistics efficiency, with particular attention to warehouse management, inventory planning, and distribution. The study also assesses the potential of integrating Preliminary Hazard Analysis (PHA) with Total Productive Maintenance (TPM) to enhance operational stability. Design/Methodology/Approach: The research was conducted in a Polish manufacturing company during 2024. Data were collected through employee questionnaires, interviews, direct observation, and PHA-based risk assessment. Ten employees participated in the survey, assessing both the probability of risk occurrence and the severity of consequences across procurement, storage, inventory management, production, and distribution stages. TPM principles were then conceptually applied to the identified risk areas. A comparative analysis was carried out to evaluate risk levels before and after the introduction of proposed improvements. Findings: The results revealed critical risks in warehouse logistics, including insufficient storage space (R=24.0), loss of stock (R=24.0), and delays in customer deliveries (R=24.4). Inventory management issues such as inaccurate demand forecasting (R=18.8) and excessive stock (R=15.2) were also identified as major threats. The application of TPM in combination with PHA reduced the overall risk level by approximately 46%, with the most significant improvement observed in the area of warehouse space management (−65%). After implementing corrective actions, most risks shifted from “unacceptable” to “tolerable” levels. Practicaal implementations: The study provides actionable recommendations for manufacturing enterprises operating under resource and space constraints. Key proposals include warehouse reorganisation and expansion, adoption of automated inventory management systems, real-time monitoring of supplies, and the integration of TPM practices with systematic risk assessment tools such as PHA. These measures improve logistics continuity, reduce operational costs, and enhance customer satisfaction. Originality/Value: This research contributes to the limited body of knowledge on risk management in the window blind manufacturing sector. By demonstrating the combined use of PHA and TPM, the study introduces a practical framework for systematically identifying and mitigating logistics risks. The findings hold value for both scholars and practitioners seeking to strengthen process reliability and competitiveness in small and medium-sized enterprises.