Risk management in complex changeovers through CFMEA: an empirical investigation

Bikram Jit Singh and Dinesh Khanduja

International Journal of Industrial and Systems Engineering, 2012, vol. 10, issue 4, 470-494

Abstract: The aim of this paper is to uncover the significance of generally ignored quick changeovers (set-ups) in complex, make-to-order, die casting foundry environments, and it discusses various bottlenecks in the way of acquiring shorter set-ups. This paper dwells with a case study in medium-scale, non-ferrous piston foundry to generate an integrated set-up reduction approach, which is utilising respective industrial engineering tools under the flag of changeover failure modes and effects analysis (FMEA), for faster set-ups. Then at last, it did the empirical analysis of the financial/non-financial benefits incurred from set-up reductions. Single minute exchange of die, define-measure-analyse-improve-control and design for changeover rules are some of the methodologies being used to recommend suitable improvements for various activities of changeovers. FMEA has already been implemented fruitfully for system, design and service sector management, but it is hard to find its application in the field of set-ups or changeover activities, which are acting as necessary evil for almost every product, process and service industry.

Keywords: quick changeover; set-up costs; product lead times; severity; FMEA; failure mode and effects analysis; risk ranking table; SMED; single minute exchange of die; economic batch quantity; die casting machines; non-value adding activities; non-ferrous piston foundries. (search for similar items in EconPapers)
Date: 2012
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