Assessment and Risk Management of Potential Hazards by Failure Modes and Effect Analysis (FMEA) Method in Yazd Steel Complex

Abstract

Background: Failure mode and effect analysis (FMEA) is a widely used quality improvement and risk assessment tool in manufacturing. The aim of this study is to assess potential hazards by failure modes and effect analysis (FMEA) method in Yazd Steel Complex. Methods: In this descriptive study, we evaluated the risks in different parts of the complex by using FMEA method and by using FMEA Worksheets (PFMEA) derived from the standard (MIL_STD-882). Failure modes and the various components and effects as using quantitative score to the risk priority (RPN) were obtained. PFMEA worksheets were completed and, we reevaluated the weaknesses part of the system. Activities related to each from the different parts of Yazd Steel Complex by using the scores risk priority (RPN) were evaluated. Then the results obtained by using SPSS software were performed by evaluation and analysis. Results: The findings showed that the steel maker lime unite and steel making ingot casting achieved the highest of RPN before and after corrective actions measures (490, 168) and environmental health unite and roll styles unite achieved the lowest of RPN before and after corrective actions measures (28, 20). Conclusions: The results show that the FMEA technique can identify a higher number of hazards than any other technique. The important point is that selection of an appropriate technique plays an important role in identifying a higher number of hazards.