Original article Application of failure mode and effect analysis (FMEA), cause and effect analysis and Pareto diagram in conjunction with HACCP to a potato chips manufacturing plant Ioannis S. Arvanitoyannis 1 * & Theodoros H. Varzakas 2 1 Department of Agriculture, Animal Production and Aquatic Environment, University of Thessaly, School of Agricultural Sciences, Fytoko Street, 38446 Nea Ionia Magnesias, Volos, Hellas (Greece) 2 Department of Processing of Agricultural Products, Technological Educational Institute of Kalamata, Kalamata School of Agricultural Sciences, Hellas (Greece) (Received 22 February 2006; Accepted in revised form 23 June 2006) Summary Failure mode and effect analysis (FMEA) model has been applied for the risk assessment of potato chips manufacturing. A tentative approach of FMEA application to the snacks industry was attempted in order to analyse the critical control points (CCPs) in the processing of potato chips. Preliminary hazard analysis was used to analyse and predict the occurring failure modes in a food chain system (potato processing and potato chips processing plant), based on the functions, characteristics and/or interactions of the ingredients or the processes, upon which the system depends. CCPs have been identified and implemented in the cause and effect diagram (also known as Ishikawa, tree diagram and fishbone diagram). Finally, Pareto diagrams were employed towards the optimisation potential of FMEA. Keywords Cause and effect analysis, failure mode and effect analysis, hazard analysis critical control points, Pareto, potato chips, preliminary hazard analysis. Introduction: risk assessment and FMEA Extension of the shelf life of potatoes is possible if careful handling is carried out by personnel. Personnel should avoid causing possible bruises on the skin of potatoes because the existing microorganisms could find a substrate to grow. Potatoes should be thor- oughly washed before their packaging to remove microorganisms from their epidermis. Potatoes should be stored under refrigeration conditions (http, 2000a,b). Risk assessment consists of hazard identification, hazard characterisation, exposure assessment and risk characterisation (Notermans et al., 1996). Moreover, according to WHO (1995), risk assessment is the scientific evaluation of known or potential adverse health effects resulting from human exposure to food- borne hazards. This case study is mainly expanded on the first stage (risk assessment) and proposes measures and actions for the successful handling of two other stages, (risk management, risk communication), based to the some extent on the model suggested by Noter- mans et al. (1996). Failure mode and effect analysis (FMEA) is proposed as long as its use will help classification of risk ruled by the factors of severity (S), probability of occurrence (O) and probability of detection (D) of raw materials at risk. Analysis is made, based both on best expert opinion and historical information for similar items, of all the ways that each component or subsystem might fail to fulfil its intended function (James, 1998). FMEA appears to be an appropriate matrix for this activity (McDermott et al., 1996). Case description Although there are not many manufacturing plants in Greece producing potato chips, all of them are certified towards a food safety system (hazard analysis critical control points – HACCP). This study aims at assessing the risk and analyse the hazards identified at each step of the potato chips processing, and at suggesting measures for the prevention and avoidance of hazards occurring in this plant. Methodology A pictorial display of a list is provided in which possible causes of problems or factors/parameters *Correspondent: Fax: +30 242 1093144; e-mail: parmenion@uth.gr International Journal of Food Science and Technology 2007, 42, 1424–1442 1424 doi:10.1111/j.1365-2621.2006.01361.x Ó 2007 The Authors. Journal compilation Ó 2007 Institute of Food Science and Technology Trust Fund