Failures prevention methods for sustainability of production-failure modes and effect analysis in a business: a case study

Abstract

Purpose- Quality activities should include all product life processes, starting from the determination of customers' demands and prejudices to the service activities provided to customers. By integrating quality-oriented practices, conducting FMEA, and employing Pareto analysis, the research aims to enhance the system's reliability, efficiency, and overall performance. This, in turn, can lead to improved customer satisfaction, reduced costs, increased productivity, and a more sustainable and successful operation in the packaging department. Methodology- In order to keep up with the rapidly developing technology, to be open to innovations with developing technologies, to be in an advantageous position against competitors and ultimately to satisfy customers and fulfil their satisfaction; it is necessary to meet the demands and needs of customers without error and at low cost. Failure Modes and Effect Analysis is applied to provide the sustainability of the production system without the failures. This study focuses on failure analysis, defining failure modes, and conducting error prevention studies within the context of businesses. The aim is to achieve zero failure and zero error by implementing effective prevention techniques. By identifying the root causes of failures and errors, businesses can develop strategies and procedures to prevent them from occurring in the first place. This proactive approach helps ensure a higher level of quality, reliability, and customer satisfaction. By emphasizing the importance of error and failure prevention, businesses can strive for continuous improvement, minimize disruptions in the production system, reduce costs associated with rework or product recalls, and maintain a strong competitive position. Implementing zero failure-error and zero error-failure prevention techniques is crucial for sustaining a reliable and efficient production system. Findings- This research shows that quality is a science that people meet in reality, not simply a theoretical concept. All organizations in the universe should take their quality management systems one step further with their approach to quality processes. In this context, the concept of zero failure-error in production or service lines has become important. By applying FMEA and considering sustainability aspects, the research aims to enhance the manufacturing process, minimize risks and failures, and contribute to sustainable practices in the food industry. Conclusion- The mentioned sample study on Failure Modes and Effects Analysis (FMEA) in food packaging within the production department of a food sector enterprise in the Marmara region highlights the importance of preventing possible failure modes and their impact on the sustainability of production. One key aspect emphasized in the study is the potential reduction of food and packaging waste by minimizing packaging or substituting oil-based materials with renewable resources. By utilizing environmentally friendly food packaging, various advantages can be achieved, including a decrease in food loss and waste, as well as a reduction in the negative environmental impact associated with managing packaging materials and waste. To accomplish this, it is crucial to address food demands throughout the entire food supply chain, with particular attention to transportation and consumption stages. In order to optimize the sustainability of food and packaging systems as a whole, it is necessary to consider the product and its packaging as an integrated system. By applying FMEA and considering the potential failure modes in food packaging, the study aims to identify areas for improvement and implement measures that enhance sustainability throughout the production process. Keywords: Failure prevention, failure mode and effect analysis, quality, sustainable production. JEL Codes: M10, L15, O14