The comparison of safety level in kilns in two gypsum production factories by Failure modes and effects Analysis (FMEA)

Failure Modes and Effects Analysis (FMEA) is a qualitative method for determination of component's fails and study of its effects on machineries. In present study, kilns safety level of two gypsum factories examine. Production process of gypsum and especially kilns structure studied. FMEAmethod conducted by four steps including determination of analysis insight, information gathering, making of list of kiln's components and filling up the FMEA tables. On the other hand, the effects of fails on production, how to fail, failure rates, severity of fails, and controls of fails considered. Furthermore, the cost of fails and priority of control methods studied. Crack and deformation of shoe plats had highest failure rate in two factories kilns. Some fails such as separation of bricks in kiln of second factory is less than the other one. Meanwhile, some fails including wrapping of kilns trunk, ring corrosion, and fracture of truster's shaft is only present in first kiln. Present study shows that technical features and design of kilns is most important factors in decreasing of failure rates and its cost.