A Case Study: A Process FMEA Tool to Enhance Quality and Efficiency of Manufacturing Industry

The study has attempted to present an effective tool for solving the problem of manufacturing process quality by executing process FMEA with proposed process control practices. This paper aims to identify and eliminate current and potential problems from a manufacturing process of cylinder head in the company through the application of Failure Mode and Effects Analysis (FMEA) for improving the reliability of sub systems in order to ensure the quality which in turn enhances the bottom line of a manufacturing industry. Thus the various possible causes of failure and their effects along with the prevention are discussed in this work. Severity values, Occurrence number, Detection and Risk Priority Number (RPN) are some parameters, which need to be determined. Furthermore, some actions are proposed which require to be taken as quickly as possible to avoid potential risks which aid to improve efficiency and effectiveness of cylinder head manufacturing processes and increase the customer satisfaction. The prevention suggested in this paper can considerably decrease the loss to the industry in term of both money time and quality