A FMEA-based approach to prioritize waste reduction in lean implementation

Abstract

Purpose

This paper presents a proposal of adaptation of the failure mode and effect analysis method to analyze wastes and define priorities for actions aimed at minimizing or eliminating these wastes based on the criteria of severity, occurrence and detection.

Design/methodology/approach

The proposition was developed in parallel to the implementation of a lean production system of a manufacturing company. A pilot application of the proposal was based on the analysis of a flow of information for order processing.

Findings

Application of the proposed procedure results in a classification of levels of priority for waste reduction of the analyzed waste modes. Following this procedure, high priority will be given to actions focused on the elimination or minimization of the most common causes of the most severe waste modes.

Originality/value

Prioritization of actions to minimize waste is essential to sustain lean production systems. However, identifying the wastes most in need of attention is not always straightforward and methods presented in the literature to evaluate leanness do not focus on waste reduction prioritization. Adoption of the proposed technique can certainly aid planning implementation and improvement of lean production programs, and in the end, it can contribute to the effectiveness and sustainability of lean production systems.

Citation

Victor B. de Souza, R. and Cesar R. Carpinetti, L. (2014), "A FMEA-based approach to prioritize waste reduction in lean implementation", International Journal of Quality & Reliability Management, Vol. 31 No. 4, pp. 346-366. https://doi.org/10.1108/IJQRM-05-2012-0058