Failure Mode Prioritization using Fuzzy Analytic Hierarchy Process: A Case Study in an Automotive Printing Factory

Abstract

This research aimed to propose a prioritization approach for identifying and addressing printing defects in the automotive component manufacturing industry. The proposed approach utilized the Fuzzy Analytic Hierarchy Process (FAHP) within the Failure Mode and Effect Analysis (FMEA) framework, adhering to the IATF 16949 global automotive component manufacturing standard. The decision-making criteria were based on the AIAG & VDA FMEA Handbook, encompassing severity (S), occurrence (O), and detection (D) for the main criteria and 4M (man, machine, method, material) and 1E (environment) for the sub-criteria. The occurring defects were collected from the case study factory, and defects were selected for prioritization using the S, O, D criteria. A group of 20 experts from various departments within the company evaluated the prioritization. The results were compared with those obtained using the traditional Risk Priority Number (RPN) and Action Priority (AP) methods. The findings revealed that all three prioritization methods yielded different results, with FAHP providing the most accurate and acceptable outcome due to its consideration of criteria weights and uncertainties in defect evaluation. The research emphasized the application of FAHP as a group decision-making tool, facilitating collaboration between cross-functional teams within the organization. Additionally, an Excel template was developed to streamline the calculation and analysis process, enabling efficient and accurate prioritization of printing defects.