Die Diplomarbeit "Applying FMEA in the knitting process" entstand in Zusammenarbeit mit der Firma Textivision in Mexiko. Das Ziel der Arbeit war, ein Qualitaetssystem (FMEA) fuer die Strickproduktion zu entwickeln und anzuwenden.
Table of Contents
1. INTRODUCTION
1.1 Diploma Thesis
1.2 The Company
2. FMEA (FAILURE MODE AND EFFECT ANALYSIS)
2.1 Background
2.2 Types of FMEA
2.3 Fundamental ideas of FMEA – why conduct FMEA
2.4 Process FMEA
3. PERFORMING A PROCESS FMEA
3.1 Defining a TEAM
3.2 Bill of materials (BOM)
3.3 Organization in the productive area
3.3.1 Production process of the knitting department
3.3.2 Workstation functions within the process
3.4 Defect overview
3.5 Cause-Effect-Diagrams
3.6 Detected defects January-August 2005
3.7 Detected defects in the working process
3.8 Risk evaluation
3.8.1 Severity (SEV)
3.8.2 Occurrence (OCC)
3.8.3 Detection (DET)
3.8.4 Risk Priority Number (RPN)
3.9 Arrangements and solutions
3.10 Checking the process - action taken to reduce the defects
3.10.1 Which checkups are already planned?
3.10.2 RPN new calculation
3.11 FMEA form
4. CONCLUSION
5. REFERENCES
6. APPENDIX
6.1 Handbook FMEA
6.2 Complete FMEA form
Objectives and Research Focus
The primary objective of this thesis is to implement a Failure Mode and Effect Analysis (FMEA) within the knitting production process to systematically identify, evaluate, and mitigate manufacturing defects. The research addresses the current lack of advanced quality assurance strategies in the textile industry by providing a structured framework to improve product quality and process reliability.
- Application of the FMEA methodology specifically within the knitting department.
- Identification and categorization of common manufacturing defects and their root causes.
- Quantification of risk through the calculation of the Risk Priority Number (RPN).
- Development of corrective measures and mistake-proofing (Poka Yoke) strategies.
- Evaluation of process improvements through comparative analysis of defect rates.
Excerpt from the Book
3.1 Defining a TEAM
To perform a process FMEA, a responsible team has to be selected. This team should have between 3 and 6 members, which should always be present during all the meetings and have certain responsibilities. These members are the “core-team”. The “support-team” is formed by employees with specialised knowledge who might sometimes be present. The support Team is helpful for creating questions in relation to the production process (fabric, machines). Both teams are also connected to the organisation, to suppliers and to the customers of the firm. They have a collective knowledge and all decisions have to be made by these groups.
Summary of Chapters
1. INTRODUCTION: An overview of the textile industry's need for advanced quality management and the emerging role of FMEA as a preventive strategy.
2. FMEA (FAILURE MODE AND EFFECT ANALYSIS): Explains the theoretical framework, history, and core components of FMEA as a systematic risk evaluation tool.
3. PERFORMING A PROCESS FMEA: Details the practical implementation steps, from team building and defect mapping to risk prioritization and corrective actions.
4. CONCLUSION: Summarizes the effectiveness of FMEA as a tool to enhance quality standards and ensure compliance within the textile production environment.
Keywords
FMEA, Process FMEA, Knitting Process, Textile Industry, Quality Assurance, Risk Priority Number, RPN, Severity, Occurrence, Detection, Failure Mode, Poka Yoke, Quality Management, Defect Analysis, Production Reliability
Frequently Asked Questions
What is the core focus of this diploma thesis?
The thesis focuses on applying the FMEA methodology within the knitting department of a textile company to detect and prevent manufacturing defects.
What are the primary themes covered in this work?
The main themes include risk identification, process analysis, quality control strategies, failure prevention, and the continuous improvement of production workflows.
What is the main objective or research question?
The goal is to demonstrate how a structured FMEA process can be used to analyze potential failure modes and improve quality in knitting production.
Which scientific methods are utilized?
The work employs systematic FMEA procedures, including the calculation of Risk Priority Numbers (RPN), Pareto diagrams for defect prioritization, and Ishikawa (Cause-Effect) diagrams for root cause analysis.
What topics are discussed in the main section?
The main section details the FMEA framework, provides a step-by-step guide to conducting a process FMEA, lists common knitting defects, and provides corrective action plans.
Which keywords best describe the research?
The research is best characterized by terms like FMEA, quality assurance, textile production, defect prevention, and process reliability.
How does the author define a successful FMEA team?
The author defines an effective team as a group of 3 to 6 members representing a "core-team" with specific responsibilities, supplemented by a "support-team" with specialized knowledge.
What is the significance of the Risk Priority Number (RPN) in this study?
The RPN is essential for prioritizing defects by multiplying severity, occurrence, and detection ratings, allowing the team to focus on the most critical manufacturing issues first.
- Citation du texte
- Dipl.Ing. Inkeri Walser (Auteur), 2006, Applying FMEA in the knitting process, Munich, GRIN Verlag, https://www.grin.com/document/186338
