Performance analysis and quality improvement using fuzzy MCDM and lean tools in a paper industry

Abstract

The paper and board manufacturing process is associated with a number of defects that hinder the quality of the product produced. This study proposes a methodology to prioritise the failures/defects and suggests suitable lean tools for process improvement. Initially, cause and effect diagram is used to identify the root causes of failures. Then, fuzzy Delphi method (FDM) is used to identify the critical failures modes. Fuzzy analytical hierarchical process (FAHP) is then used to arrive at the weights for failure mode and effect analysis (FMEA) criterion: severity, occurrence and detection using the expert's opinion. Fuzzy technique for order of preference by similarity to ideal solution (fuzzy TOPSIS) is then applied to rank the prioritised failures based on the weights calculated using FAHP. Based on FAHP and fuzzy TOPSIS-based FMEA analysis, five failure modes namely crease, felt impression, stiffness variation, blade line and fluff are identified as the most critical. The prioritised design requirements are identified using fuzzy quality function deployment (FQFD) and the improvement methods are suggested by using lean tools such as 5S and total productive maintenance (TPM).