Quality and Efficiency Improvement Through Process FMEA—A Case Study

Abstract

AbstractA failure mode and effect analysis (FMEA) helps to identify potential failure modes which can occur in any industry. These failures can lead to major quality defects in the product. In this study, we used a process FMEA approach in a maize flake producing company to enhance the quality and efficiency of the process. A field study approach was used to understand the process, potential failure modes present, and its causes in the process. We developed an FMEA model to evaluate the impact of these failure modes on the process. According to the effects of the potential failure mode on the process and product, a severity ranking was assigned to the respective potential failure mode. Using this severity ranking, detectability in the company and occurrences of the failure modes, a risk priority number (RPN) was assigned to these failure modes. By prioritizing the failure modes, some corrective actions were suggested to the company. These actions reduced the occurrences of the failure modes leading to a reduction in the RPN associated with the potential failure modes. These RPN reductions led to enhance the quality of product and overall increment in productivity and efficiency of the process.KeywordsFood industryFailure mode and effect analysis (FMEA)Risk priority number (RPN)Potential failure modeQuality enhancement