Implementation Of FMEA And Waste Elimination In Company Muehlbauer (Assembly Company)

Teoh, Yong Siang (2011) Implementation Of FMEA And Waste Elimination In Company Muehlbauer (Assembly Company). Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

FMEA is used widely in the industry to search and quantify the potential design and process failure before they occur on the system observed, and take corresponding action to prevent or eliminate the potential failures observed. In this project, the subject of study is a machine (DSlOK) assembled in Company Muehlbauer and the concern is the potential failure modes occur during the assembly process of the machine. The implementation steps of FMEA on the machine studied have been developed through its integration with other lean tools and project management tools. Process stream map, Bill of Material (BOM), and Work Breakdown Structure (WBS) are used to identify the components of the machine, their functions and how they relate to each other. After the FMEA is tabulated, Pareto chart is used to track out the significant few to be emphasized and the components are taken care during assembly process. The results of implementation steps are then evaluated using Value Stream Mapping (VSM), which is another lean tool, to examine if the assembly lead time of FMEA has been reduced through the implementation of FMEA. The result shows that the assembly time of the machine reduced is 70 minutes and the wasted non-value added time reduced is 98 minutes, which are 14.83% and 59.89% respectively. In the end of the project, the tools and ways used in standardizing the FMEA are summarized. Further study of the project would be the development of corresponding software of the standardized steps to get a faster and accurate result in the future.

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