Environmental Risk Management in Automaker Industries Case Study: Pre-Paint Part of Iran Khodro Company (IKCO)

Despite abundant resources, the automotive industry is reported to adversely impact the environment owing to the use of heavy machinery, diverse and governmental management policies for car production per hour, remarkable employed labor force, production cycle timing, etc. For this purpose, many studies involving environmental risk management have been conducted. To this aim, the present study has been carried out in pre-paint part No. 2 of IKCO (preparation process). In this regard, using FUZZY FMEA and VIKOR methods, the identified risks were assessed and reformative measures and solutions were classified, respectively. A total of 15 individuals considered HSE experts of IKCO were selected as a statistical sample size according to the Morgan table. Consequently, the high level risks were identified and appropriate solutions were suggested to reduce the environmental effects, and according to achieved scores, “torch adjustments based on compliance report” with the objective of reducing air pollution was selected as the compromise solution. IKCO should consider torch adjustment based on compliance report actions as its first priority.

APPLICATION OF FUZZY FMEA TO PERFORM AN EXTENSIVE RISK ANALYSIS IN MARITIME TRANSPORTATION ENGINEERING

The nature of maritime transportation involves numerous hazards, which can lead to serious consequences for human life, marine environment and ship. Therefore, achieving a high level of safety is recognised as paramount in maritime industry (Akyuz, 2016). In order to achieve this purpose, this paper prompts a fuzzy based Failure Mode and Effects analysis (FMEA) to perform an extensive risk analysis in the maritime transportation industry. The method has capable of identifying potential failures and calculating risk priority number (RPN) by capturing nonlinear casual relationships between the failures. The proposed method is applied to hatch cover failures in operational aspects in bulk carrier ships since potential failures of hydraulic hatch covers have serious concerns for ship owners. Besides its theoretical insight, the paper has practical benefits to ship owners, superintendents as well as safety professionals by identifying potential failure and offering early corrective actions.

FUZZY FMEA APPLICATION TO IDENTIFICATION RISK IN-PROCESS PRODUCTION OF TOYOTA HI-ACE WIRING HARNESS PRODUCT

In product manufacture, the high failure rate problem of produce product is the number of product defects. Several types of defects have a high enough percentage. To solve this problem, we need to identify the failures and to get the assessment information of the three risk factors. Our research using the traditional FMEA method at the production of Wiring Harness products to shows the current condition of various modes of failure in those areas. This study focuses on implementing fuzzy FMEA to identify the potential risks that may occur along with the assembling of the Wiring Harness process. The fuzzy FMEA approach is preventing product and process problems before they occur, this paper is also expected to result in some mitigation effort that can be applied to improve the Wiring Harness production process. With the Fuzzy FMEA method, we have found the highest FRPN value that shows the highest defect such as damage insulation is 8.5, damage terminal is 8.5, and the damaged part is 8.5 and the highest RPN from the traditional FMEA is damage insulation (324). To solve this problem, we propose to use the fishbone diagram and give suggestions for improvements to the highest failure modes that are damaged insulation.

ANALISIS RISIKO PRODUKSI KARET RIBBED SMOKED SHEET (STUDI KASUS DI KEBUN MERBUH, PTPN IX )

Karet Ribbed Smoked Sheet merupakan salah satu produk karet olahan konvensional yang sedang dikembangkan di Indonesia dan menjadi salah satu komoditas ekspor favorit. Perusahaan milik negara yang bertugas mengolah lateks menjadi RSS yaitu PTPN IX, akan tetapi dalam proses produksinya PTPN IX banyak mengalami kendala produksi yang disebabkan oleh berbagai faktor. Penelitian ini bertujuan untuk menganalisis: 1). kuantitas produksi pada RSS kebun Merbuh PTPN IX, 2). kualitas produksi RSS, 3). tingkat risiko produksi yang terjadi pada proses produksi RSS, 4). risiko utama yang menjadi penyebab kegagalan dan 5). rumusan strategi mitigasi yang tepat untuk meminimalkan dampak risiko. Penelitian dilaksanakan pada bulan Februari hingga April 2021 di Kebun Merbuh, PTPN IX Desa Trayu Kecamatan Singorojo Kabupaten Kendal. Penelitian menggunakan metode studi kasus. Metode analisis data menggunakan metode kuantitatif meliputi Koefisien Variasi (KV) dan Fuzzy Failure Mode and Effect (Fuzzy FMEA). Penentuan responden dengan teknik purposive. Sumber data penelitian menggunakan data primer dan data sekunder. Hasil penelitian menunjukkan tingkat risiko pada pabrik RSS Kebun Merbuh tergolong sangat tinggi dan mengalami fluktuasi yang ekstrim dengan nilai 24%. Terdapat 3 dari 17 risiko yang teridentifikasi dengan nilai FRPN tertinggi yaitu: kerusakan sekat aluminium dengan nilai 8,74, standar kadar karet kering tidak sesuai dengan nilai 7,63 dan prakoagulasi dini pada lateks dengan nilai 6,87. Mitigasi risiko meliputi aspek ketaatan, aspek tenaga kerja, dan aspek teknis perlu diterapkan guna mereduksi risiko.

A DMAIC Integrated Fuzzy FMEA Model: A Case Study in the Automotive Industry

The growing competitiveness in the automotive industry and the strict standards to which it is subject, require high quality standards. For this, quality tools such as the failure mode and effects analysis (FMEA) are applied to quantify the risk of potential failure modes. However, for qualitative defects with subjectivity and associated uncertainty, and the lack of specialized technicians, it revealed the inefficiency of the visual inspection process, as well as the limitations of the FMEA that is applied to it. The fuzzy set theory allows dealing with the uncertainty and subjectivity of linguistic terms and, together with the expert systems, allows modeling of the knowledge involved in tasks that require human expertise. In response to the limitations of FMEA, a fuzzy FMEA system was proposed. Integrated in the design, measure, analyze, improve and control (DMAIC) cycle, the proposed system allows the representation of expert knowledge and improves the analysis of subjective failures, hardly detected by visual inspection, compared to FMEA. The fuzzy FMEA system was tested in a real case study at an industrial manufacturing unit. The identified potential failure modes were analyzed and a fuzzy risk priority number (RPN) resulted, which was compared with the classic RPN. The main results revealed several differences between both. The main differences between fuzzy FMEA and classical FMEA come from the non-linear relationship between the variables and in the attribution of an RPN classification that assigns linguistic terms to the results, thus allowing a strengthening of the decision-making regarding the mitigation actions of the most “important” failure modes.