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Int. J. Mech. Eng. & Rob. Res. 2012 Piyush Kumar Pareek et al., 2012
FMEA IMPLEMENTATION IN A FOUNDRY IN
BANGALORE TO IMPROVE QUALITY AND
RELIABILITY
Piyush Kumar Pareek
1
*, Trupti V Nandikolmath
1
and Praveen Gowda
1
*Corresponding Author: Piyush Kumar Pareek, piyushpareek88@gmail.com
Failure Mode and Effect Analysis (FMEA) is a technique to identify and prioritize potential failures
of a process. This paper reports the description of FMEA methodology and its implementation in
a foundry in reducing rejections of bushes. It is used as a tool to assure products quality and as
a mean to improve operational performance of the process. The work was developed in an
Indian foundry, in co-operation with part of the internal staff chosen as FMEA team members
and was focused on the study of core making process. The problems identified in the various
steps of core making process contributing for high rejection are studied and analyzed in terms
of RPN to prioritize the attention for each of the problem. The monetary loss due to core rejection
is considered as measure of risk.
Keywords: Core, FMEA, Failure mode, Risk priority number
INTRODUCTION
Process FMEA is used to solve problems due
to manufacturing processes. It starts with a
process flow chart that shows each of the
manufacturing steps of a product. The potential
failure modes and potential causes for each
of the process steps are identified, followed
by the effects of failures on the product and
product end users. The risks of these effects
are then assessed accordingly as shown in
Figure 1 (Xu et al., 2002).
ISSN 2278 – 0149 www.ijmerr.com
Vol. 1, No. 2, July 2012
© 2012 IJMERR. All Rights Reserved
Int. J. Mech. Eng. & Rob. Res. 2012
1
Department of Industrial Engineering & Management, DSCE, Bangalore, Karnataka 560078, India.
Basic Terms Used
Failure: The loss of an intended function of a
device under stated conditions.
Failure Mode: The manner by which a failure
is observed; it generally describes the way the
failure occurs.
Failure Effect: Immediate consequences of
a failure on operation, function or functionality,
or status of some item.
Research Paper