Monitoring the Most Critical Error-based Failures in Carpet Production by Failure - Mode - and - Effects Analysis

There is always a probability of recurring failures in a manufacturing system. These failures disturb the output of a system quantitatively and qualitatively, and on the whole they are menace to the system's productivity. This paper introduces a technique called "failure-mode-and-effects analysis (FMEA)" to recognize or monitor and reduce harmful effects of the most critical errors in a carpet manufacturing system. This method requires a team of inspecting members to discuss the type of failures and their potential risk by classifying each failure under a grade called "risk priority number (RPN)". The failures with highest RPN are the most critical type of failures for which corrective actions must be preferentially taken to increase the quality of the production. In this research work, FMEA technique is adopted in a carpet manufacturing system to evaluate and monitor the type and quality of the failures, while presenting solutions to eliminate them most effectively.