Process Failure Modes and Effects Analysis (PFMEA) and Improvements on Valve Seizure Issue in Engine Assembly


Abstract views: 45 / PDF downloads: 17

Authors

DOI:

https://doi.org/10.5281/zenodo.15099329

Keywords:

Internal combustion engines, engine assembly factory, production assembly processes

Abstract

This study analyzes and improves defects encountered in the production processes of internal combustion engines in an engine assembly plant. Process Failure Modes and Effects Analysis (PFMEA) was utilized to detect, assess, and minimize these defects. To enhance its effectiveness, 6M analysis, Ishikawa diagrams, root cause analysis, and statistical process control (SPC) techniques were applied. The research primarily focuses on the valve seizure issue in the cylinder head assembly process, identifying root causes and implementing preventive and corrective actions. As a result, critical defects were significantly reduced, process efficiency improved, and annual defect-related costs decreased. This study provides valuable insights into quality management and continuous improvement in the automotive industry. The systematic application of PFMEA enables proactive error detection, better process control, and enhanced quality standards. Findings contribute to developing a structured framework for quality management in similar manufacturing environments.

References

AIAG, 2008. Potential Failure Mode and Effects Analysis (FMEA) Reference Manual (4. ed). Chrysler LLC, Ford Motor Company, General Motors Corporation.

Alkaç, M., 2024. Deniz taşımacılığında nikel madeni yükünün sıvılaşmasından kaynaklanan deniz kazalarının bulanık hata ağacı analizi (FFTA) ve hata türleri ve etkileri analizi (FMEA) yöntemleri ile incelenmesi. Yüksel Lisans Tezi, Karadeniz Teknik Üniversitesi Fen Bilimleri Enstitüsü, Trabzon.

Altınışık, A., Hugul, O., 2020. The seven-step failure diagnosis in automotive industry. Engineering Failure Analysis, 116: 104702.

Baghbani, M., Iranzadeh, S., Bagherzadeh Khajeh, M., 2019. Investigating the relationship between RPN parameters in fuzzy PFMEA and OEE in a sugar factory. Journal of Loss Prevention in the Process Industries, 60: 221-232.

Bowles, J.B., Pelaez, C.E., 1995. Fuzzy logic prioritization of failures in a system failure mode, effects and criticality analysis. Reliability Engineering and System Safety, 50(2): 203-213.

Cândea, G., Kifor, S., Constantinescu, C., 2014. Usage of case-based reasoning in FMEA-driven software. Procedia CIRP, 25: 93-99.

Corporation, C., Company, F.M., Corporation, G.M., 2008. Advanced Product Quality Planning (Apqp) And Control Plan, 2. Baskı, s. 111.

Dyah Susanti, H., 2023. Risk prevention of plywood product defects using Failure Mode Effect Analysis (FMEA) in the Indonesian plywood processing industry. Wood Material Science & Engineering, 18(6): 2049-2059.

Gilchrist, W., 1993. Modelling failure modes and effects analysis. International Journal of Quality & Reliability Management, 10(5).

Gueorguiev, T., Kokalarov, M., Sakakushev, B., 2020. Recent trends in FMEA methodology. 2020 7th International Conference on Energy Efficiency and Agricultural Engineering (EE&AE), Konferans Bildiri Kitabı, 12-14 Kasım, Ruse, Bulgaristan, s. 1-4.

Hoyle, D., 2005. Automotive Quality Systems Handbook (Second Edition ed.).

Ishikawa, K., 1982. Guide to Quality Control.

Johnson, K.G., Khan, M.K., 2003. A study into the use of the process failure mode and effects analysis (PFMEA) in the automotive industry in the UK. Journal of Materials Processing Technology, 139(1): 348-356.

Kök, N., Yıldız, M.S., 2023. New generation FMEA method in automotive industry: an application. Journal of Turkish Operations Management, 7(1): 1630-1643.

Kornek, D., Bert, C., 2024. Process failure mode and effects analysis for external beam radiotherapy: Introducing a literature-based template and a novel action priority. Zeitschrift für Medizinische Physik, 34(3): 358-370.

Liu, H.C., Chen, X.Q., Duan, C.Y., Wang, Y.M., 2019. Failure mode and effect analysis using multi-criteriadecision making methods: A systematic literature review. Computers & Industrial Engineering, 135: 881-897.

Lundgren, M., Hedlind, M., Kjellberg, T., 2015. Model-driven process planning and quality assurance. Procedia CIRP, 33: 209-214.

Maisano, D.A., Franceschini, F., Antonelli, D., 2020. dP-FMEA: An innovative failure mode and effects analysis for distributed manufacturing processes. Quality Engineering, 32(3): 267-285.

Mikos, W.L., Ferreira, J.C.E., Botura, P.E.A., Freitas, L.S., 2011. A system for distributed sharing and reuse of design and manufacturing knowledge in the PFMEA domain using a description logics-based ontology. Journal of Manufacturing Systems, 30(3): 133-143.

Mokhtarzadeh, M., Rodríguez-Echeverría, J., Zeren, Z., Van Noten, J., Gautama, S., 2024. Pure data-driven machine learning challenges for pFMEA: A case study. IFAC-PapersOnLine, 58(19): 658-663.

Ouyang, L., Che, Y., Yan, L., Park, C., 2022. Multiple perspectives on analyzing risk factors in FMEA. Computers in Industry, 141: 103712.

Pantazopoulos, G., Tsinopoulos, G., 2005. Process failure modes and effects analysis (PFMEA): A structured approach for quality improvement in the metal forming industry. Journal of Failure Analysis and Prevention, 5(2): 5-10.

Pazireh, E., Sadeghi, A.H., Ahadi, H., 2017. Design and application of a quality control system using FMEA approach in textile production lines. Journal of Textiles and Apparel, 17: 89-94.

Plinta, D., Golinska, E., Dulina, Ľ., 2021. Practical application of the new approach to FMEA method according to AIAG and VDA reference manual. Communications - Scientific Letters of the University of Zilina, 23(4): B325-B335.

Pop, L.D., Elod, N., 2015. Improving product quality by implementing ISO / TS 16949. Procedia Technology, 19: 1004-1011.

Scipioni, A., Saccarola, G., Centazzo, A., Arena, F., 2002. FMEA methodology design, implementation and integration with HACCP system in a food company. Food Control, 13(8): 495-501.

Shah, L.A., Etienne, A., Siadat, A., Vernadat, F.B., 2013. A process-oriented risk assessment methodology for manufacturing processes. IFAC Proceedings Volumes, 46(9): 216-221.

Stamatis, D.H., 2003. Failure Mode and Effect Analysis. Quality Press.

Trappey, A. J.C., Hsiao, D.W., 2008. Applying collaborative design and modularized assembly for automotive ODM supply chain integration. Computers in Industry, 59(2): 277-287.

VDA, AIAG., 2019. AIAG & VDA FMEA Handbook-Automotive Industry Action Group, AIAG ve VDA, 237.

Wang, L., Hodges., 2021. Automatic modeling and fault diagnosis of car production lines based on first-principle qualitative mechanics and semantic web technology. Advanced Engineering Informatics, 49: 101-248.

Yousaf, M.U., Aized, T., Shabbir, A., Ahmad, M., Nabi, H.Z., 2023. Automobile rear axle housing design and production process improvement using failure mode and effects analysis (fmea). Engineering Failure Analysis, 154: 107649.

Zheng, X., He, Y., Chen, Z., Li, J., Lu, J., Yu, S., 2025. Built-in reliability-oriented R-KQC intelligent identification based on SA-HHO and proactive reliability assurance strategy. Computers & Industrial Engineering, 200: 110817.

Published

2025-03-28

How to Cite

MENDİ , T. C., & AYDOĞAN , H. (2025). Process Failure Modes and Effects Analysis (PFMEA) and Improvements on Valve Seizure Issue in Engine Assembly. MAS Journal of Applied Sciences, 10(1), 161–178. https://doi.org/10.5281/zenodo.15099329

Issue

Section

Articles