Title: Integration of modified FMEA approach with Industry 4.0 technologies to improve reliability of lean systems

Authors: Subburaman Karthik; Balaji Kuppusamy

Addresses: Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, No. 42, Avadi-VelTech Road, Vel Nagar, Avadi, Chennai – 600 062, Tamil Nadu, India ' Department of Mechanical Engineering, Vel Tech Rangarajan Dr. Sagunthala R&D Institute of Science and Technology, No. 42, Avadi-VelTech Road, Vel Nagar, Avadi, Chennai – 600 062, Tamil Nadu, India

Abstract: Many organisations are using lean tools with Industry 4.0 technology these days to enhance the sustainability of their lean manufacturing systems. This article contributes by combining a lean tool (modified FMEA) with Industry 4.0 technologies to improve the dependability of lean systems. Under the four lean subsystems of personnel, equipment, materials, and schedules, a redesigned FMEA framework incorporating Industry 4.0 technologies is proposed. From the mapping of lean wastes, inventory accounts for 39% of total waste, overproduction accounts for 23% of total waste, defects account for 22% of total waste, non-utilised talent accounts for 16% of total waste based on RAV calculation from modified FMEA table. Also based on RPN calculation from the modified FMEA table, Inventory accounts for 45% of total waste, overproduction accounts for 23%, of total waste, defects account for 19% of total waste, non-utilised talent accounts for 13% of total waste.

Keywords: lean; Industry 4.0; personnel; equipment; materials; schedules.

DOI: 10.1504/IJISE.2024.138895

International Journal of Industrial and Systems Engineering, 2024 Vol.47 No.2, pp.216 - 236

Received: 18 Dec 2021
Accepted: 17 Sep 2022
Published online: 03 Jun 2024 *

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