IMPROVING PRODUCTION CAPACITY IN MANUFACTURING COMPANIES USING FAILURE MODES AND EFFECTS ANALYSIS, FMEA

Failure Modes and Effects Analysis (FMEA) is a technique for the systematic analysis of failures. It is a major tool in reliability analysis. FMEA exists in system, process and design. The term failure connotes the frequency of failure occurrence. In this paper, a functional beverages manufacturing company which operates as a brewery is considered. The methodology comprises the analysis criteria, ranking for the occurrence probability, severity and detection of failures. The risk assessment matrix (RAM) was developed to show how severity relates with occurrence. Three-line production plants were considered: Returnable Glass Bottle (RGB) Line One, Poly Ethylene Tricilicate (PET) Line Two and RGB Line Three. Different failure prone units were analyzed. These were, for RGB Lines One and Three, Uncaser, Bottle Transport Conveyor (BTC), Bottle Washer, Filler and Coding Machine. For PET Line Two, BTC, Filler, Coding Machine, Labeler and Shrink Wrapper were analyzed. The Risk Priority Numbers (RPNs) were calculated. The analysis results showed that production capacity in the company can be improved by redesigning its production process in line with the findings especially in accordance with the different values of the RPNs.

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