An improved modified FMEA model for prioritization of lean waste risk

Abstract

Purpose

Proposing an improved model for evaluating criticality of non-value added (waste) in operation is necessary for realizing sustainable manufacturing practices. The purpose of this paper is concerning on improvement of the decision support model for evaluating risk criticality lean waste occurrence by considering the weight of modified FMEA indices and the influence of waste-worsening factors causing the escalation of waste risk magnitude.

Design/methodology/approach

Integration of entropy and Taguchi loss function into decision support model of modified FMEA is presented to rectify the limitation of previous risk reprioritization models in modified FMEA studies. The weight of the probability components and loss components are quantified using entropy. A case study from industry is used to test the applicability of the integration model in practical situation.

Findings

The proposed model enables to overcome the limitations of using subjective determination on the weight of modified FMEA indices. The inclusion of the waste-worsening factors and Taguchi loss functions enables the FMEA team to articulate the severity level of waste consequences appropriately over the use of ordinal scale in ranking the risk of lean waste in modified FMEA references.

Research limitations/implications

When appraising the risk of lean waste criticality, ignorance on weighting of FMEA indices may be inappropriate for an accurate risk-based decision-making. This paper provides insights to scholars and practitioners and others concerned with the lean operation to understand the significance of considering the impact of FMEA indices and waste-worsening factors in evaluating criticality of lean waste risks.

Practical implications

The method adopted is for quantifying the criticality of lean waste and inclusion of weighting of FMEA indices in modified FMEA provides insight and exemplar on tackling the risk of lean waste and determining the most critical waste affecting performability of company operations.

Originality/value

Integration of the entropy and Taguchi loss function for appraising the criticality of lean waste in modified FMEA is the first in the lean management discipline. These findings will be highly useful for professionals wishing to implement the lean waste reduction strategy.

Citation

Sutrisno, A., Gunawan, I., Vanany, I., Asjad, M. and Caesarendra, W. (2020), "An improved modified FMEA model for prioritization of lean waste risk", International Journal of Lean Six Sigma, Vol. 11 No. 2, pp. 233-253. https://doi.org/10.1108/IJLSS-11-2017-0125