Product defects are not created equal: prioritizing production process improvements

Abstract

Despite manufacturers’ efforts to improve quality, customers frequently experience product defects. Based on expectation confirmation theory, hypotheses concerning the effects of experiencing product defects on overall quality perceptions and loyalty to the product manufacturer have been developed and tested. Our results show that experiencing product defects related to performance, ease of use, prestige and versatility damages overall quality perceptions and decrease customer loyalty to the product manufacturer, either fully or partially mediated through overall quality perceptions. Contrary to frequent claims in the literature, experiencing even a single product defect per quality dimension damages customers’ quality perceptions. Furthermore, different types of product defect damage customer perceptions of product quality and loyalty to the manufacturer differently. Building on these results, we develop a defect typology and a portfolio visualization that allows operations managers to prioritize production process improvements.