Title: A modified FMEA technique for ranking wastes to optimise the implementation of the lean manufacturing system

Authors: Muhammad Rizwan Khan; Nabeel Khalid; Syed Hussain Mustafa Gillani; Hakeem Ur Rehman; Ayesha Khan; Sajjad Ahmad Baig

Addresses: National Textile University, Sheikhupura Road, Faisalabad 37610, Pakistan ' National Textile University, Sheikhupura Road, Faisalabad 37610, Pakistan ' Kohsar University, Murree Punjab House Campus, Murree, Pakistan ' Institute of Quality and Technology Management, University of the Punjab, Lahore, Pakistan ' National Textile University, Sheikhupura Road, Faisalabad 37610, Pakistan ' National Textile University, Sheikhupura Road, Faisalabad 37610, Pakistan

Abstract: Lean adoption is becoming increasingly essential for reducing waste and maximising performance standards. However, there are a few obstacles that can hinder the performance increase during lean implementation. In order to deliver premium goods to diverse demand markets throughout the past decade, corporations have resorted to cost reduction and manufacturing innovation in response to pressure from the competition. Our study's primary worry is that textile companies in Pakistan do not account for actual working conditions when building lean frameworks. We also attempt to determine why lean adoption in Pakistani textile industries failed. This paper's methodology consists of three steps: hierarchical tree diagrams (HTDs), gap analysis, and a modified FMEA technique utilised in the third phase to concentrate on the threat and rank the waste according to their priority numbers. When the suggested method is implemented, the analysed waste mechanisms are prioritised in order of waste reduction importance. Following this procedure, initiatives focused at eliminating or decreasing the most widespread causes of the most severe waste modes would be accorded a high level of importance. Adopting the provided methodology can unquestionably aid in program formulation, implementation, and enhancement, hence, boosting the effectiveness and long-term viability of lean manufacturing systems.

Keywords: lean implementation; waste reduction; occurrence; severity; detection; FMEA approach.

DOI: 10.1504/IJPQM.2025.149970

International Journal of Productivity and Quality Management, 2025 Vol.46 No.3, pp.397 - 432

Received: 16 Feb 2023
Accepted: 06 Sep 2023
Published online: 19 Nov 2025 *

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