Reduction of production loss in production process by using failure modes/effects analysis (FMEA) technique

Abstract

            Failure Modes/Effects Analysis (FMEA) is one of various methods applied in Design for Manufacturing (DFM) methodology of concurrent engineering used to effectively reduce product loss in production process. FMEA has provided a disciplined technique to identify and help eliminate potential concerns in design and processes. Responsibility for the preparation of a FMEA rests on specific individuals; however, FMEA input should be a team effort. In this case study, FMEA was used as the tool to find out root causes of failure in carbon black production process. Three categories of root causes of failure were made, based on FMEA criteria called “RPN (risk priority number) score”, the higher RPN score representing worse situation. The outcome of this case study was cost saving. Each category provided a certain amount of cost saving after FMEA was implemented. The defect rates were reduced from 46.70% to 27.41% in the first group, 14.54% to 9.71% in the second group, and 6.35% to 3.45% in the third group. Cost saving anticipated from this case study was approximately 11,200,000 Baths/year or 27% of total loss in year 2000.