Ceren ARSLAN KAZAN, Halil KORUCA, Buket KARATOP

NESNELERİN İNTERNETİ DESTEKLİ HTEA VE BULANIK HTEA ANALİZİ İLE MALİYET OPTİMİZASYONU

Küresel rekabet ortamı işletmeleri yüksek kaliteli ve düşük maliyetli ürünler üretmeye zorlamaktadır ve bu konuda stratejiler geliştirmektedirler. Aynı zamanda üretimdeki rislerin belirlenerek bunların (bu risklerin) kalite ve maliyete etkilerinin giderilmesi gerekir. FMEA yöntemi risk analizinde etkili sonuçlar veren bir yöntemdir. Bu çalışmada ürün ve yarı mamül çeşitliliği fazla olan bir işletmenin talaşlı imalat atölyesinde geleneksel FMEA ve Fuzzy FMEA analizleri yapılmıştır. Gömülü bir dizi veri işleme kartının desteğiyle çalışan İOT teknolojisi ile gerçek zamanlı veriler elde edilmiştir. Bu verilerde üretimde darboğaz oluşturan hatalar belirlenmiştir ki bu veriler makine operatörüne bağlı olmadan elde edilmiştir. Üç aylık dönem için yapılan analiz ile en riskli konularda iyileştirmeler yapılarak üretim maliyetlerinde toplamda %6 düşüş sağladığı maliyet ile ilgili kayıtlarında gözlemlenmiştir. Aynı zamanda geleneksel FMEA ve fuzzy FMEA sonuçları karşılaştırılmıştır.

Anahtar Kelimeler:

Hata Türü ve Etkileri Analizi (HTEA), Bulanık HTEA, Üretim, Risk Analizi, Maliyet Optimizasyonu

COST OPTMIZATION WITH INTERNET SUPPORTED FMEA AND FUZZY FMEA ANALYSIS

The global competitive environment forces businesses to produce high-quality and low-cost products and they develop strategies in this regard. At the same, production risks should be identified and their effects on quality and cost should be minimized. The FMEA method is a risk analysis method that produces effective results. Traditional FMEA and Fuzzy FMEA analyses were conducted in the machining workshop of an enterprise with a wide range of products and semi-products in this study. Real-time data was obtained with the help of an embedded set of data processing cards, which use IoT technology. These data have been used to identify errors that cause production bottlenecks, and they were obtained without relying on the machine operator. Improvements were made in the riskiest subjects during the three-month analysis, and it was discovered in the cost records that a total reduction of 6% in production costs was achieved. Simultaneously, traditional FMEA and fuzzy FMEA results were compared.

Keywords:

Failure Mode and Effect Analysis (FMEA), Fuzzy FMEA, Production, Risk Analyses, Cost Optimization,

PDF

___

Besterfield, D.H., Besterfield, C., Besterfield, G., & Besterfield, M. (1999). Total Quality Management (3rd ed.). America, Prentice Hall Publishing.
Çeber, Y. (2010). Application of failure mode and effects analysis method (FMEA) in manufacturing industry (Master's thesis, Dokuz Eylül University, Izmir). Access address https://acikerisim.deu.edu.tr/xmlui/handle/20.500.12397/10839.
Çevik, O., and Aran, G. (2009). Failure mode effects analysis (FMEA) in the quality improvement process and an application in piston production. Journal of Social and Economic Research, 8(16), 241-265. Retrieved from https://dergipark.org.tr/tr/pub/susead/issue/28423/302689.
Çiğdem, M. (2006). Manufacturing methods (2nd edn.). İstanbul, Çağlayan Bookstore Publishing,
Dağcı, B. (2019). Analysis of error types and effects in the quality improvement process and investigation of errors by data mining: an application in the machining industry. (Unpublished master's thesis). Karabuk University Institute of Science and Technology Industrial Engineering Department, Karabük.
Filz, M. A., Langner, J. E. B., Hermann, C., and Thiede, S. (2021). Data-driven failure mode and effect analysis (FMEA) to enhance maintenance planning. Computers in Industry, 129, 103451. doi: 10.1016/j.compind.2021.103451.
Fuzzification and Defuzzification. (t.y.) Difference between fuzzification and defuzzification içinde. 16 Mart 2022 tarihinde https://www.geeksforgeeks.org/difference-between-fuzzification-and-defuzzification/ adresinden erişildi.
Ghani, A. J., Harron, C. H. C., Hamdan, S. H., Said, A. Y., and Tomadi, A. Y. (2013). Failure mode analysis of carbide cutting tools used for machining titanium alloy. Ceramics International, 39(4), 4449-4456. doi: 10.1016/j.ceramint.2012.11.038.
Gönen, D. (2004). Failure modes and effects analysis and an application study (Master's thesis, Balıkesir University, Balıkesir). Access address info:eu-repo/semantics/openAccess
Gül, B. (2001). Failure mode and effects analysis in quality management (Unpublished master's thesis). Gazi University Institute of Science and Technology Industrial Engineering Department, Ankara.
Güngör, F., & Paçal, K. (2004). The effect of risk analysis in planning of machining system. IV. Proceedings of the National Production Research Symposium. Turkey: Conference publication.
Güngör, F., & Paçal, K. (2006). The effect of risk analysis on the planning of the machining system. UAS 2006, VI. National Production Research Symposium (1-6 pp). Turkey.
Huang, G. Q. (2000). Failure mode and effect analysis (FMEA) over the www. The International Journal of Advanced Manufacturing Technology, 16 (8), 603-608.
Hung, S. W., and Chen, T. K. (2019). Disclosing AlN ceramic substrate process failure mode and effect analysis. Microelectronics Reliability, 103, 113508. doi: 10.1016/j.microrel.2019.113508.
Kusumadewi, S. (2002). Analisis dan desain sistem fuzzy menggunakan toolbox matlab. Yogyakarta: Graha Ilmu979-3289-02-3 Daftar Pustaka: hlm.
Li, H., Diaz, H., and Soares, C. G. (2021). A failure analysis of floating offshore wind turbines using AHP-FMEA methodology. Ocean Engineering, 234, 109261. doi: 10.1016/j.oceaneng.2021.109261.
Lo, H. W., Liou, J. J. H., Haung, C. N., and Chaung, Y. C. (2019). A novel failure mode and effect analysis model for machine tool risk analysis. Reliability Engineering and System Safety, 183, 173-183. doi: 10.1016/j.ress.2018.11.018.
Mariajayaprakash, A., & Senthilvelan T. (2013). Failure detection and optimization of sugar mill boiler using FMEA and taguchi method. Engineering Failure Analysis, 30, 17-26. doi: 10.1016/j.engfailanal.2012.12.010.
Mirzaoğlu, İ., and Saritas, M. (2008). Automation of a semolina production system using PLC and SCADA (Master's thesis, Gazi University, Ankara). Access address http://hdl.handle.net/20.500.12602/150129.
Mzougui, I., and Felsoufi, Z. E. (2019). Proposition of a modified FMEA to improve reliability of product. Procedia CIRP, 84, 1003-1009. doi: 10.1016/j.procir.2019.04.315.
Sánchez, M., Paz Moral, M., and Ramoscelli, G. (2020). Activity-based costing in smart and connected products production enterprises. Growing Science, 6, 33-50. doi: 10.5267/j.ac.2019.6.002.
Söylemez, C. (2006). Failure mode and effects analysis occupational safety application. (Unpublished master's thesis). Gazi University, Institute of Science and Technology Industrial Engineering, Ankara.
Stamatis D. H. (1995). Failure Mode And Effects Analysis – FMEA from Theory To Execution (2nd e.). America, Asq Pr Quality Press Publishing.
Şen, Z. (2004). Mühendislikte Bulanık (Fuzzy) Mantık ile modelleme prensipleri (Modelling principles with the Fuzzy Logic in engineering). Su Vakfı Publications.
Ünğan, M. C. (2017). Failure mode effects analysis and an application in automotive parts production. Journal of Business Science (JOBS), 5(2), 217-245. doi: 10.22139/jobs.321887.
Wang, L.-X. (2008). Adaptive fuzzy systems and control – design and stability analysis.Prentice Hall0130996319.
Yang, G. (2007). Life cycle reliability engineering. New Jersey: John Wiley &Sons, Inc978-0-471-71529-0.
Yee T. M., Ahmed, S., and Quader, M. A. (2014, November). Process behaviour and capability analysis for improvement of product quality in car-door glass manufacturing. 5th Brunei International Conference on Engineering and Technology in Brunei. https://www.crossref.org/iPage?doi=10.1049%2Fcp.2014.1059.