Investigations on failure prevention through the application of foundry total failure mode and effect analysis

Abstract

Continuous improvement in the process has to be done to improve the competitive advantage of the organization Currently manufacturing community are increasing their thrust in the area of Total Failure Mode Effect Analysis which is becoming a key competitive success factor in retaining customers amidst the fierce competition without reducing the profit margin As a result during the recent period TFMEA initiatives are increasingly applied informally to achieve failure prevention in organizations Yet the fruitfulness of TFMEA initiatives in manufacturing organizations is not adequately nourished in a holistic manner This is the reason why the currently adopted informal TFMEA initiatives do not adequately identify and address the failures and defects actually happening in the manufacturing process of organizations Hence creation of sector specific dynamic TFMEA in modern organizations has been necessitated In order to create a sector specific dynamic TFMEA in manufacturing arena a model named as Foundry Total Failure Mode Effect Analysis based on TFMEA practice has been developed There are many process failures and their associated defects that occur during the casting process in the foundry FTFMEA facilitates the prioritizing of corrective actions in order to prevent reduce and eliminate the failures thus minimizing the losses occurring in the organizations