FAILURE MODES AND EFFECT ANALYSIS IN A SOFT DRINKS MANUFACTURING INDUSTRY

ABSTRACT
A Failure Modes and Effects Analysis (FMEA) allows possible determination of the probability of failure modes in a process, system or even machines if properly undertaken. This enhances reliability of products, processes and even machine effectiveness and efficiency.
The research gives an FMEA evaluation of a soft drink producing plant using historical maintenance data and failure modes of system. The severity, frequency of occurrence of failure and likelihood of failure detection are assigned. The Risk Priority Number (RPN) was then calculated for the production operating processes.
In all, the filling process which developed some faults among which are; (a) Speed loss (b) Falling of bottles from the feeder arm during bottle washing (c) Broken center wheel guide (d) Faulty filler encoder, gave the various RPN respectively, 100,30,30 and 6 respectively. This meant that it developed faults which in comparison with the other process were problematic. Hence, ensuring proper speed for bottle filling, and generally proper maintenance would help in reducing the risk associated with the fault. Similarly, the bottle washing process based on calculation gave a relatively high RPN which meant that prompt attention and consequently recommendations were
proffered.