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Enhanced FMEA: An integrative approach of fuzzy logic-based FMEA and collective process capability analysis

Abstract The aim of this study is to modify and enhance the quantitative/mathematical features of both computational and analytical aspects of the process failure modes and effects analysis (FMEA). For this purpose, a hybrid approach including the Fuzzy Logic-based FMEA (FFMEA) and collective process capability analysis (CPCA) has been developed in three phases. First, failure modes have been defined based on lack of quality in quality characteristics under investigation, and then, they have been prioritised using FFMEA. Second, the most critical failure has been selected for statistical analysis using CPCA, leading to the corrective actions in the third phase. The proposed approach was investigated in an electrical-equipment-manufacturing company. Findings indicated that the diameter deviation in Insulator A was the most critical failure effect caused by a rightward mean shift of 0.32 cm. In addition, Cpk has been improved from 0.41 to 1.12, and defective products have been reduced from 115,083.09 to 336.98 parts per million.