Abstract
This paper presents a methodology called lean failure mode and effects analysis (LFMEA) using fuzzy weighted geometric mean for prioritising lean failure modes. Fuzzy lean priority number (FLPN) is calculated to prioritise lean failure modes using factors like occurrence, severity and detection. Fuzzy linear programming models and alpha-cut techniques are used for ranking failure modes. For defuzzification of FLPNs, alpha-level set-based centroid defuzzification method is used. Based on the FLPN values, lean tools are selected to eliminate the lean failures. The future state implemented with selected lean tools has shown encouraging results from case studies. Lead time, cycle time and non-value added time are reduced by 11.3%, 14% and 6.1% for a casting industry and 47.3%, 31.3% and 67.2% respectively for an auto components manufacturing industry. The unnecessary movements, manpower and inventory are reduced to greater levels. This selection methodology confirms positive effects on productivity improvement process.
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