A modified FMEA approach to enhance reliability of lean systems

Rupy Sawhney · Christian Sonntag · Prasanna V. Rao · Clayton Jerrett Capizzi

108 citations0/0 files storedInternational Journal of Quality & Reliability Management

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Quality and Supply Management Reliability and Maintenance Optimization Management and Optimization Techniques

Abstract

Purpose The purpose of this paper is to encourage the integration of Lean principles with reliability models to sustain Lean efforts on a long‐term basis. It seeks to present a modified FMEA that will allow Lean practitioners to understand and improve the reliability of Lean systems. The modified FMEA approach is developed based on the four critical resources required to sustain Lean systems: personnel, equipment, materials, and schedules. Design/methodology/approach A three‐phased methodology approach is presented to enhance the reliability of Lean systems. The first phase compares actual business and operational conditions with conditions assumed in Lean implementation. The second phase maps potential deviations of business and operational conditions to their root cause. The third phase utilizes a modified Failure Mode and Effects Analysis (FMEA) to prioritize issues that the organization must address. Findings A literature search shows that practical methodologies to improve the reliability of Lean systems are non‐existent. Research limitations/implications The knowledge database involves many tedious calculations and hence needs to be automated. Originality/value The paper has defined Lean system reliability, developed a conceptual model to enhance the Lean system reliability, developed a knowledge base in the form of detailed hierarchical root trees for the four critical resources that support our Lean system reliability, developed a Risk Assessment Value (RAV) based on the concept of effectiveness of detection using Lean controls when Lean designer implements Lean change, developed modified FMEA for the four critical resources.

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References

1992The machine that changed the world 2006Critical success factors for lean implementation within SMEs 1994From lean production to the lean enterprise 2007Risk evaluation in failure mode and effects analysis using fuzzy weighted geometric mean 2003Modified failure mode and effects analysis using approximate reasoning 1999JIT Manufacturing: A Survey of Implementations in Small and Large U.S. Manufacturers 2005Reprioritization of failures in a system failure mode and effects analysis by decision making trial and evaluation laboratory technique 2008Lean, take two! Reflections from the second attempt at lean implementation

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