FAILURES PREVENTION METHODS FOR SUSTAINABILITY OF PRODUCTION-FAILURE MODES AND EFFECT ANALYSIS IN A BUSINESS: A CASE STUDY

Yıl 2023, Cilt: 10 Sayı: 3, 134 - 151, 30.09.2023

Ayşenur Erdil , Hikmet Erbıyık

https://doi.org/10.17261/Pressacademia.2023.1810

Öz

Purpose- Quality activities should include all product life processes, starting from the determination of customers' demands and prejudices to the service activities provided to customers. By integrating quality-oriented practices, conducting FMEA, and employing Pareto analysis, the research aims to enhance the system's reliability, efficiency, and overall performance. This, in turn, can lead to improved customer satisfaction, reduced costs, increased productivity, and a more sustainable and successful operation in the packaging department.
Methodology- In order to keep up with the rapidly developing technology, to be open to innovations with developing technologies, to be in an advantageous position against competitors and ultimately to satisfy customers and fulfil their satisfaction; it is necessary to meet the demands and needs of customers without error and at low cost. Failure Modes and Effect Analysis is applied to provide the sustainability of the production system without the failures. This study focuses on failure analysis, defining failure modes, and conducting error prevention studies within the context of businesses. The aim is to achieve zero failure and zero error by implementing effective prevention techniques. By identifying the root causes of failures and errors, businesses can develop strategies and procedures to prevent them from occurring in the first place. This proactive approach helps ensure a higher level of quality, reliability, and customer satisfaction. By emphasizing the importance of error and failure prevention, businesses can strive for continuous improvement, minimize disruptions in the production system, reduce costs associated with rework or product recalls, and maintain a strong competitive position. Implementing zero failure-error and zero error-failure prevention techniques is crucial for sustaining a reliable and efficient production system.
Findings- This research shows that quality is a science that people meet in reality, not simply a theoretical concept. All organizations in the universe should take their quality management systems one step further with their approach to quality processes. In this context, the concept of zero failure-error in production or service lines has become important. By applying FMEA and considering sustainability aspects, the research aims to enhance the manufacturing process, minimize risks and failures, and contribute to sustainable practices in the food industry.
Conclusion- The mentioned sample study on Failure Modes and Effects Analysis (FMEA) in food packaging within the production department of a food sector enterprise in the Marmara region highlights the importance of preventing possible failure modes and their impact on the sustainability of production. One key aspect emphasized in the study is the potential reduction of food and packaging waste by minimizing packaging or substituting oil-based materials with renewable resources. By utilizing environmentally friendly food packaging, various advantages can be achieved, including a decrease in food loss and waste, as well as a reduction in the negative environmental impact associated with managing packaging materials and waste. To accomplish this, it is crucial to address food demands throughout the entire food supply chain, with particular attention to transportation and consumption stages. In order to optimize the sustainability of food and packaging systems as a whole, it is necessary to consider the product and its packaging as an integrated system. By applying FMEA and considering the potential failure modes in food packaging, the study aims to identify areas for improvement and implement measures that enhance sustainability throughout the production process.

Anahtar Kelimeler

Failure prevention, failure mode and effect analysis, quality, sustainable production

Kaynakça

• Angellier-coussy, H., Guillard, V., Guillaume, C. and Gontard, N. (2013). Role of packaging in the smorgasbord of action for sustainable food consumption. Agro Food Industry, 23, 15–19.
• Aydan, M. and Kaya, S. (2017). Hata Türü ve Etkileri Analizi (HTEA): Üniversite Hastanesinde Bir Uygulama, Hacettepe Sağlık İdaresi Dergisi, 20(4), 475-502.
• Baysal, M.E. and Canıyılmaz, E. E.T. (2002). Otomotiv Yan Sanayiinde Hata Türü ve Etkileri Analizi, Teknoloji, 5(1-2), 83-90.
• Baraçlı, H. (1998). Sıfır Hataya Ulaşmada Poka-Yoke Tekniği ve Ayakkabı Sektöründe Uygulama Çalışması, Yayınlanmamış Doktora Tezi, Yıldız Teknik Üniversitesi, Fen Bilimleri Enstitüsü, İstanbul.
• Beitzen-Heineke, E. F., Balta-Ozkan, N. and Reefke, H. (2017). The prospects of zero-packaging grocery stores to improve the social and environmental impacts of the food supply chain. Journal of Cleaner Production, 140, 1528–1541.
• Bektaş, D. (2007). Hata Türü Etkileri Analizi ve Film Kaplı Tablet Üretiminde Uygulanması, Yayınlanmamış Yüksek Lisans Tezi, Marmara Üniversitesi Sosyal Bilimler Enstitüsü, İstanbul.
• Bertoluci, G., Leroy, Y. and Olsson, A. (2014). Exploring the environmental impacts of olive packaging solutions for the European food market. Journal of Cleaner Production, 64, 234–243.
• Büsser, S. and Jungbluth, N. (2009). The role of flexible packaging in the life cycle of coffee and butter. The International Journal of Life Cycle Assessment, 14(1), 80–91.
• Canbolat, R. (2008). Hata Türü Etkileri Analizi’nde Analitik Ağ Süreci ve Bulanık Mantık Uygulaması, Yayınlanmamış Yüksek Lisans Tezi, Sakarya Üniversitesi, Fen Bilimleri Enstitüsü, Sakarya.
• Çevik, O. and Aran, G. (2009). Kalite İyileştirme Sürecinde Hata Türü Etkileri Analizi (Fmea) ve Piston Üretiminde Bir Uygulama, Sosyal Ekonomik Araştırmalar Dergisi, 8(16), 241-265.
• Chin, K.S., Wang, Y.M., Poon, G.K.K. and Yang, J.B. (2009). Failure mode and effects analysis using a group-based evidential reasoning approach, Computers & Operations Research, 36, 768–1779.
• Coffigniez, F., Matar, C., Gaucel, S., Gontard, N., Guilbert, S. and Guillard, V.V. (2021). The use of modeling tools to better evaluate the packaging benefice on our environment. Frontiers in Sustainable Food Systems, 5(April), 1-22.
• Eryürek, Ö. F. and Tanyaş, M. (2003). Hata türü ve etkileri analizi yönteminde maliyet odaklı yeni bir karar verme yaklaşımı. İTÜ Dergisi Seri D: Mühendislik 2(6), 31 – 40.
• EEA (2016) Environmental indicator report 2016—In support to the monitoring of the 7th Environment Action Programme. European Environmental Agency. https://www.eea.europa.eu//publications/ environmental-indicator-report-2016. Accessed October 2017.
• European Council (1994) Directive 94/62/EC on packaging and packaging waste. Official Journal of the European Union, 365, 10–23.
• Fellows, P. and Axtell, B. (2002). Packaging materials. In: Fellows P, Axtell B, editors. Appropriate food packaging: materials and methods for small businesses. Essex, U.K.: ITDG Publishing, 25–77.
• Franceschini, F. and Maurizio Galetto, M. (2001). A New Approach for Evaluation of Risk Priorities of Failure Modes in FMEA. International Journal of Production Research, 39(13), 2991-3002.
• Geyer, R., Jambeck, J. R. and Law, K. L. (2017). Production, use, and fate of all plastics ever made. Science Advances, 3(7), 1-5.
• Golan, E., Krissoff, B., Kuchler, F., Calvin, L., Nelson, K. and Price, G. (2004). Traceability in the U.S. food supply: economic theory and industry studies. Agricultural economic report nr 830. Washington, DC: Economic Research Service, U.S. Dept. of Agriculture, 48.
• Guillard, V., Gaucel, S., Fornaciari, C., Angellier-Coussy, H., Buche, P. and Gontard, N. (2018). The next generation of sustainable food packaging to preserve our environment in a circular economy context. Frontiers in Nutrition, 5, 254-266.
• Hekmatpanah, C.M., Shahin, A. and Ravichandran, N.(2011). The application of FMEA in the oil industry in Iran: The case of four litre oil canning process of Sepahan Oil. African Journal of Business Management 5(8), 3019-3027.
• Hueting, R. and Reijnders, L. (1998), Sustainability is an objective concept, Ecological Econonomics, 27(2), 139-47.
• İnce, M. E. (2023). Olası Hata Türü Ve Etkileri Analizi (FMEA), Etüd-Araştırma Servisi, Konya Ticaret Odası. http://www.kto.org.tr/d/file/olasi-hata-turu-ve-etkileri-analizi-(fma).pdf, Acesss Date : 10.05.2023.
• Jantzen, N.R and Alexander, M. (Eds (1987). A logistical view of packaging, Problems in Marketing Logistics, Pitman, New York, NY, 129-155.
• Lewis H. (2012). Designing for sustainability. In Packaging for Sustainability, Verghese K, Lewis H, Fitzpatrick L (eds). Springer: London, 41-106.
• Lewis, H., Verghese, K. and Fitzpatrick, L. (2010). Evaluating the sustainability impacts of packaging: the plastic carry bag dilemma. Packaging Technology and Science, 23, 145–160.
• Licciardello, F. (2017). Packaging, blessing in disguise, Review on its diverse contribution to food sustainability. Trends Food Science Technology, 65, 32–39.
• Matar, C., Gaucel, S., Gontard, N., Guilbert, S. and Guillard, V. (2010). Predicting shelf-life gain of fresh strawberries ‘Charlotte cv’ in modified atmosphere packaging. Postharvest Biol Technology, 142, 28–38.
• Molina‐Besch, K. and Pålsson, H. (2020). A simplified environmental evaluation tool for food packaging to support decision‐making in packaging development. Packaging Technology and Science, 8, 1-17.
• Munasinghe, M. (1993), Environmental Economics and Sustainable Development, The World Bank, Washington, D.C., 95. https://documents1.worldbank.org/curated/en/638101468740429035/pdf/multi-page.pdf.
• Özkök, F. and Gümüş, F. (2009). Sürdürülebilir turizmde bilginin önemi. Yönetim Bilimleri Dergisi, 7(1), 51-71.
• Pauer, E., Wohner, B., Heinrich, V. and Tacker, M. (2019). Assessing the environmental sustainability of food packaging: an extended life cycle assessment including packaging-related food losses and waste and circularity assessment. Sustainability, 11(3), 1-21.
• Pillay, A. and Wang, J. (2003). Modified failure mode and effects analysis using approximate reasoning. Reliability Engineering and System Safety, 79, 69–85.
• Prendergast, G. P. (1995). The EC directive on packaging and packaging waste. Logistics Information Management, 8(3), 10–17.
• Principato, L., Secondi, L. and Pratesi, C.A. (2015). Reducing food waste: an investigation on the behaviour of Italian youths. British Food Journal, 117(2), 731-748.
• Rahman, A., Sarkar, A., Yadav, O. P., Achari, G. and Slobodnik, J. (2021). Potential Human Health Risks Due to Environmental Exposure to Nano- and Microplastics and Knowledge Gaps: A Scoping Review. Science of the Total Environment, 757, 143872, 1-13.
• Ragusa, A., Svelato, A., Santacroce, C., Catalano, P., Notarstefano, V., Carnevali, O., … Giorgini, E. (2021). Plasticenta: First evidence of microplastics in human placenta. Environment International, 146, 1-8.
• Scipioni, A., Saccarola, G. , Centazzo , A. and Arenaü F. (2002). FMEA methodology desing, implementation and integration with HACCP system in a food company. Food Control, 13(8), 495-501.
• Silvenius, F., Grönman, K., Katajajuuri, J.-M., Soukka, R., Koivupuro, H.-K. and Virtanen, Y. (2013). The role of household food waste in comparing environmental impacts of packaging alternatives. Packaging Technology and Science, 27(4), 277–292.
• Slinger, M. (1992). To practise QFD with success requires a new approach to product design. Kontinuert Forbedring, 2, 20-21.
• Sezgin, M. and Kalaman, A. (2008). Turistik destinasyon çerçevesinde sürdürülebilir turizm yönetimi ve pazarlaması. Selçuk Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, 19, 429-437.
• Su, X., Deng, Y., Mahadevan, S. and Bao, Q. (2012). An improved method for risk evaluation in failure modes and effects analysis of aircraft engine rotor blades. Engineering Failure Analysis, 26, 164-174.
• Tencati, A., Pogutz, S., Moda, B., Brambilla, M. and Cacia, C. (2016). Prevention policies addressing packaging and packaging waste: Some emerging trends. Waste Management, 56, 35–45.
• Tua, C., Nessi, S., Rigamonti, L., Dolci, G. and Grosso, M. (2017). Packaging waste prevention in the distribution of fruit and vegetables: An assessment based on the life cycle perspective. Waste Management & Research, 35(4), 400–415.
• Verghese, K., Lewis, H., Lockrey, S. and Williams, H. (2015). Packaging’s role in minimizing food loss and waste across the supply chain. Packaging Technology and Science, 28(7), 603–620.
• Wang, Y., Cheng, G., Hu, H. and Wu, W. (2012). Development of a risk-based maintenance strategy using FMEA for a continuous catalytic reforming plant. Journal of Loss Prevention in the Process Industries, 25(6), 958–965.
• Williams, H., Lindström, A., Trischler, J., Wikström, F. and Rowe, Z. (2020). Avoiding food becoming waste in households – The role of packaging in consumers’ practices across different food categories. Journal of Cleaner Production, 265, 1-14.
• Williams, H., Wikström, F., Otterbring, T., Lofgren, M. and Gustafsson, A. (2012). Reasons for household food waste with special attention to packaging. Journal of Cleaner Production, 24, 141-148.
• Williams, H. and Wikström, F. (2011). Environmental impact of packaging and food losses in a life cycle perspective: a comparative analysis of five food items. Journal of Cleaner Production, 19(1), 43–48.
• Williams, H. Wikström, F. and Löfgren, M. (2008). A life cycle perspective on environmental effects of customer focused packaging development. Journal of Cleaner Production, 16(7), 853–859.
• Wikström, F. and Williams, H. (2010). Potential environmental gains from reducing food losses through development of new packaging - a life-cycle model. Packaging Technology and Science, 23(7), 403–411.
• Wikström, F., Williams, H., Trischler, J., Rowe, Z. (2019). The importance of packaging functions for food waste of different products in households. Sustainability, 11(9), 2641-2657.
• Wohner, B., Pauer, E., Heinrich, V. and Tacker, M. (2019). Packaging-related food losses and waste: an overview of drivers and issues. Sustainability, 11(1), 264-279.
• Xiao, N., Huang, H-Z., Li, Y., He, L. and Jin, T. (2011). Multiple failure modes analysis and weighted risk priority number evaluation in FMEA. Engineering Failure Analysis, 18(4), 1162-1170.
• Yılmaz, B. S. (2000). Hata türü ve etki analizi. Dokuz Eylül Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, 2(4), 133-150.