Welding Products Defects Analysis with Fault Tree Analysis and Failure Modes and Effects Analysis

Abstract

In manufacturing companies, high number of defects translates to high costs. Some types of products that have defects can be reworked to minimize wastes. However, not all types of products can be reworked, especially welding products. Companies need to find ways to reduce defects before they occur. Reduced defects mean better sustainability, both in economical terms and in ecological terms. This paper discusses the results of a field study conducted in an automotive company that uses Resistance Spot Welding (RSW) in its processes. Fault Tree Analysis (FTA) and Failure Modes and Effects Analysis (FMEA) method is used in identifying causes of defects and in developing action plan to reduce Risk Priority Numbers (RPN) as a way to reduce defects and defects-related costs.