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The aim of this research was to call attention to the implementation of failure mode and effects analysis (FMEA) in a collaborative environment, the issues occurred in the implementation process, and a tool that can be used by all parties in a collaborative environment for FMEA process.

The discussion includes the procedure of an integrated FMEA approach, how to implement the procedure in a supply chain, and the common problems occurred in its implementation in automotive industry under a collaborative environment.

The research provided an example of inconsistency in the ranking of severity, occurrence, and detection to show that the inconsistency may delay FMEA implementation in a supply chain.

This study offered guidelines for manufacturing industry in correcting the problems in FMEA applications, so companies can adopt their FMEA process into a collaborative supply chain environment. This paper also demonstrated a Microsoft EXCEL‐based tool that can ease the FMEA process in a collaborative environment for determining sampling size, reliability and confidence level for tests in design verification and control plan as a part of integrated FMEA process.

To show that handling warranty returns is essential in a supply chain for product/process improvement and that the major step in resolving warranty return problems is to correctly classify the returned parts and identify the problem(s).

Demonstrates two classification processes that separate available warranty returned parts into correct categories.

The result of these two processes provides pertinent parties in the supply chain more accurate warranty failure information, so the companies involved can precisely pin‐point the source of the failure cause in the products and improve the product's design and manufacturing. Meanwhile, it also resolves potential conflicts in a supply chain and assigns responsibility to the right party to cover incurred warranty repair cost. Its applications can enhance quality and reliability management in a supply chain and streamline the reverse logistics operations in the chain.

This paper offers companies an effective procedure in reducing wrongly classified warranty returns and makes root cause analysis of warranty returns more efficient.