New Generation FMEA Method in Automotive Industry: An Application

Öz

It is aimed to gain study substantiality by making an application for risk analysis study in the automotive industry. To bring to the literature the current point of risk analyzes used in FMEA methods applied in the automotive industry. At the same time, it is aimed to improve a problem experienced in the process of an operating in the automotive supplier industry with the risk analysis method. Failure Mode and Effects Analysis (FMEA) from risk analysis which is strong method to identifying and managing of the risks of potential failures occurring from product, process, service and system. Three methods were used in FMEA risk analysis in the study. AIAG FMEA Handbook fourth edition 2008, VDA-4 standard and new generation AIAG&VDA FMEA handbook, 2019. In this study, a Process FMEA study was prepared for the surface coating preparation process used by an automotive supplier industry. According to the results of the risk analysis, corrective actions were defined and prepared after the P-FMEA study. Afterwards, the necessary investments were made by the company management and the risks were minimized. With this investment, an innovative and technological application was integrated by ensuring the transition of the process from the human factor to automation. In addition, differences and current information about FMEA evaluation methods used in the automotive industry have been brought to the literature

Anahtar Kelimeler

• FMEA
• PFMEA
• FMEA in Automotive Industry
• Risk Management
• RPN
• VDA
• AIAG

Kaynakça

1. Automotive Industry Action Group (AIAG). (2008). Potential Failure Mode and Effects Analysis (FMEA) Reference Manual. Chryesler LLC, Ford Motor Company, General Motors Corporation
2. AIAG (Automotive Industry Action Group) and VDA (Verband der Automobilindustrie). 2019. Failure mode and effects analysis – Design FMEA and process FMEA handbook. Southfield, MI
3. Bao, J., Johansson, J. and Zhang, J. (2017), “An occupational disease assessment of the mining industry’s occupational health and safety management system based on FMEA and an improved AHP model”, Sustainability, Vol. 9 No. 1, p. 94. https://doi.org/10.3390/su9010094
4. Bertsche, B. (2008), Reliability in Automotive and Mechanical Engineering: Determination of Component and System Reliability, Springer, Berlin.
5. Carpitella, S., Certa, A., Izquierdo, J., & La Fata, C. M. (2018). A combined multi-criteria approach to support FMECA analyses: A real-world case. Reliability Engineering & System Safety, 169, 394–402. https://doi.org/10.1016/j.ress.2017.09.017 Chao.L.P, and Ishii. K., (2007). Design Process Error Proofing: Failure Modes and Effects Analysis of the Design Process”. Journal of Mechanical Design. Vol. 129 Issue 5, pp. 491-501. https://doi.org/10.1115/1.2712216
6. Chemweno, P., Pintelon, L., Van Horenbeek, A. and Muchiri, P. (2016), “Development of a novel methodology for root cause analysis and selection of maintenance strategy for a thermal power plant: a data exploration approach”, Engineering Failure Analysis, Vol. 66, pp. 19-34. https://doi.org/10.1016/j.engfailanal.2016.04.001
7. Chen, C. C. (2013). A Developed Autonomous Preventive Maintenance Programme Using RCA and FMEA. International Journal Of Production Research, 51(18), 5404-5412. https://doi.org/10.1080/00207543.2013.775521
8. Cornes, R., and Stockton, T. R. (1998). Fmea as An Integral Part of Vessel Design And Construction:Producing a Fault Tolerant Dp Vessel. In Dynamic Positioning Conference. http://dynamic-positioning.com/proceedings/dp1998/Dcornes1.pdf

9. Eubanks, C. F., Kmenta, S., and Ishii, K. (1997). Advanced Failure Modes and Effects Analysis Using Behavior Modeling. In ASME Design Engineering Technical Conferences(pp.14-17. https://doi.org/10.1115/DETC97/DTM-3872
10. Geramian, A., Shahin, A., Minaei, B. and Antony, J. (2019), “Enhanced FMEA: an integrative approach of fuzzy logic-based FMEA and collective process capability analysis”, Journal of the Operational Research Society, Vol. 71 No. 5, pp. 800-81. https://doi.org/10.1080/01605682.2019.1606986
11. Gilchrist, W. (1993). Modelling Failure Modes and Effects Analysis. International Journal Of Quality & Reliability Management, 10(5). https://doi.org/10.1108/02656719310040105
12. Gueorguiev, T., Kokalarov, M., & Sakakushev, B. (2020, November). Recent trends in FMEA methodology. In 2020 7th International Conference on Energy Efficiency and Agricultural Engineering (EE&AE) (pp. 1-4). IEEE. https://doi.org/10.1109/EEAE49144.2020.9279101
13. Hekmatpanah, M. (2011). The evaluation and application of FMEA in Sepahan Oil Co. International Journal of Industrial and Manufacturing Engineering, 5(4), 769-774. https://doi.org/10.5281/zenodo.1334119
14. Hettiarachchi, R. L., Koomsap, P., & Ardneam, P. (2021). VIKOR power law-based customer-oriented FMEA with complete unique risk priority numbers. International Journal of Quality & Reliability Management. https://doi.org/10.1108/IJQRM-06-2020-0197
15. Koomsap, P. and Charoenchokdilok, T. (2018), “Improving risk assessment for customer-oriented FMEA”, Total Quality Management and Business Excellence, Vol. 29 Nos 13-14, pp. 1563-1579. https://doi.org/10.1080/14783363.2016.1274229
16. Kok, N. and Yildiz M.S. (2017a). Problem Solving with Failure Mode And Effect Analysis ( Fmea) Method An Applicatıon in Automotıive Parts Industry. Master’s Degree, Duzce University
17. Kok, N. and Yildiz M.S. (2017b). Problem Solving with Failure Mode And Effect Analysis ( Fmea) Method An Applicatıon in Automotıive Parts Industry. 3 rd International Annual Meeting of Sosyoekonomi Society, April 28-29, 2017 Ankara / Turkey, Hacettepe University, 340-346
18. Liu, H.C., You, J.X., Lin, Q.L. and Li, H. (2014), “Risc assessment in system FMEA combining fuzzy weighted average with fuzzy decision-making trial and evaluation laboratory”, International Journal of Computer Integrated Manufacturing, Vol. 28 No. 7, pp. 701-714. https://doi.org/10.1080/0951192X.2014.900865
19. Liu, H. C., X. Q. Chen, C. Y. Duan, and Y. M. Wang. 2019a. Failure mode and effect analysis using multi-criteria decision making methods: A systematic literature review. Computers & Industrial Engineering 135:881–97. https://doi.org/10.1016/j.cie.2019.06.055
20. Madzík, P., & Shahin, A. (2020). Customer categorization using a three-dimensional loyalty matrix analogous to FMEA. International Journal of Quality & Reliability Management. https://doi.org/10.1108/IJQRM-05-2020-0179
21. Maisano, D. A., Franceschini, F., & Antonelli, D. (2020). dP-FMEA: An innovative Failure Mode and Effects Analysis for distributed manufacturing processes. Quality Engineering, 32(3), 267-285. https://doi.org/10.1080/08982112.2020.1729991
22. Matzler, K., Bailom, F., Hinterhuber, H.H., Renzl, B. and Pichler, J. (2004), “The asymmetric relationship between attribute-level performance and overall customer satisfaction: a reconsideration of the importance-performance analysis”, Industrial Marketing Management, Vol. 33 No. 4, pp. 271-277. https://doi.org/10.1016/S0019-8501(03)00055-5
23. Narayanagounder, S., and Gurusami, K. (2009). A new approach for prioritization of failure modes in design FMEA using ANOVA. World Academy of Science, Engineering and Technology, 49(524-31). https://www.academia.edu/download/6634826/v49-96.pdf
24. Pantazopoulos, G. and Tsinopoulos, G. (2005). Process Failure Modes and Effects Analysis (PFMEA): A Structured Approach for Quality İmprovement in The Metal Forming Industry”, Journal of Failure Analysis and Prevention, Volume 5, Issue 2, pp. 5-10. https://doi.org/10.1361/15477020522933
25. Pazireh, E., Sadeghi, A. H., and Shokohyar, S. (2017) Analyzing the enhancement of production efficiency using FMEA through simulation-based optimization technique: A case study in apparel manufacturing. Cogent Engineering, 4(1), 1284373. https://doi.org/10.1080/23311916.2017.1284373
26. Rezaee, M. J., S. Yousefi, M. Valipour, and M. M. Dehdar. 2018. Risk analysis of sequential processes in food industry integrating multi-stage fuzzy cognitive map and process failure mode and effects analysis. Computers & Industrial Engineering 123:325–37. https://doi.org/10.1016/j.cie.2018.07.012
27. Ristic, O., Iricanin, B.D. and Mijailovic, V. (2016), “Dynamic modelling and simulation of power transformer maintenance costs”, Serbian Journal of Electrical Engineering, Vol. 13 No. 2, pp. 285-299. https://doi.org/10.2298/SJEE1602289R
28. Sankar, R.N. and Prabhu, B.S. (2001), “Modified approach for prioritization of failures in a system failure mode and effects analysis”, International Journal of Quality and Reliability Management, Vol. 18 No. 3, pp. 324-336. https://doi.org/10.1108/02656710110383737
29. Scipioni, A., Saccarola, G., Centazzo, A., and Arena, F. (2002). FMEA Methodology Design, Implementation and Integration With HACCP System in A Food Company. Food control, 13(8), 495-501. https://doi.org/10.1016/S0956-7135(02)00029-4
30. Segismundo, A. and Miguel, A. C. P. (2008). Failure Mode and Effects Analysis (FMEA) in The Context of Risk Management in New Product Development: A Case Study in An Automotive Company. International Journal of Quality & Reliability Management, Volume 25, Issue 9, pp. 899 - 912. https://doi.org/10.1108/02656710810908061 Shaker, F., Shahin, A. and Jahanyan, S. (2019), “Developing a two-phase QFD for improving FMEA: an integrative approach”, International Journal of Quality and Reliability Management, Vol. 36 No. 8, pp. 1454-1474. https://doi.org/10.1108/IJQRM-07-2018-0195
31. Shi, S., Fei, H., & Xu, X. (2019). Application of a FMEA method combining interval 2-tuple linguistic variables and grey relational analysis in preoperative medical service process. IFAC-PapersOnLine, 52(13), 1242–1247. https://doi.org/10.1016/j.ifacol.2019.11.368
32. Shishebori, D., Akhgari, M. J., Noorossana, R., and Khaleghi, G. H. (2015). An Efficient Integrated Approach to Reduce Scraps of Industrial Manufacturing Processes: A Case Study From Gauge Measurement Tool Production Firm. The International Journal of Advanced Manufacturing Technology, 76(5-8), 831-855. https://doi.org/10.1007/s00170-014-6273-x
33. Society of Automotive Engineers (SAE J1739). (2008). Potential Failure Mode and Effects Analysis in Design (Design FMEA) and Potential Failure Mode and Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) and Effects Analysis for Machinery (Machinery FMEA). SAE International.
34. Stamatis, D. H. (2003). Failure Mode And Effect Analysis: FMEA from Theory to Execution. ASQ Quality Press.
35. Stoll, H. W. (1999). Product design methods and practices. CRC Press.
36. Subriadi, A. P., and Najwa, N. F. (2020). The consistency analysis of failure mode and effect analysis (FMEA) in information technology risk assessment. Heliyon, 6(1), e03161. https://doi.org/10.1016/j.heliyon.2020.e03161
37. Vahdani, B., Salimi, M., and Charkhchian, M. (2015). A New FMEA Method by Integrating Fuzzy Belief Structure and TOPSIS to Improve Risk Evaluation Process. The International Journal Of Advanced Manufacturing Technology, 77(1-4), 357-368. https://doi.org/10.1007/s00170-014-6466-3
38. Verband der Automobilindustrie (VDA-4). (2012). Quality Management in the Automobile Industry. Volume 4: Product and Process FMEA, 1-70
39. Yeh, R. H., and Hsieh, M. H. (2007). Fuzzy Assessment of FMEA for A Sewage Plant. Journal of the Chinese institute of industrial engineers, 24(6), 505-512. https://doi.org/10.1080/10170660709509064
40. Zhao, X. (2011). A Process Oriented Quality Control Approach Based on Dynamic SPC and FMEA Repository. International Journal Of Industrial Engineering, 18(8).
41. Wang, Y., Cheng, G., Hu, H., Wu, W. (2012). Development of risk-based maintenance strategy using FMEA for a continuous catalytic reforming plant. Journal of Loss Preventation in the Process Industries 25, 958-965. https://doi.org/10.1016/j.jlp.2012.05.009