Enhancing product quality control through applications of FMEA

Product quality is the most vital factor for manufacturers’ survival. As an effective quality control technique, FMEA (Failure Mode Effect Analysis) has been put into widespread use. However, improper, unsystematic and isolated FMEA applications in product design and manufacturing process design have lowered its effectiveness greatly. This research aims to develop an integrated FMEA framework which can guide correct FMEA applications. The focus of the research is to interrelate and provide traceability of the potential failures of functions of product design and the manufacturing processes. The objectives are to: (1) synthesise the best practices of FMEA applications through a comprehensive literature review; (2) identify the gap between FMEA application performances and best practices through document research, staff interviews and questionnaire in an aerospace company; (3) develop an integrated FMEA framework designed to interrelate and provide traceability of potential failures of functions of product design and manufacturing processes; (4) validate the framework through expert judgement in collaboration with the aerospace company. This research has proposed an integrated FMEA framework. It has five parts, which mean 5 stages for applying FMEA. To guarantee enough management support and required resources, it is first necessary to establish management awareness and commitment; then the system for mandatory, systematic and correct FMEA applications must be established; subsequently, staff training to develop a sound understanding of FMEA applications, FMEA implementation for risk assessment and elimination and auditing process for continuous improvement are proposed sequentially. According to the expert judgement, the framework can guide correct and systematic FMEA applications in the collaborative aerospace company, focusing more attention on defect elimination and thereby enhancing product quality control.