Where Do We Start Our Improvement Program? Business Level Failure Mode and Effects Analysis with Methodology and Case Studies

It is the last in a series of three books focused on improving operational performance in large industrial facilities. It expands on a chapter common to the first two - Making Common Sense Common Practice, and What Tool? When? A Management Guide for Selecting the Right Improvement Tools by providing additional detail and case studies on how to use an analysis tool called a Business Level FMEA (Failure Modes and Effects Analysis). In particular, the case studies and analysis technique are illustrated by using fictitious characters that play specific roles, including their dialogue, such that it will take you through the analysis methodology as if it were happening in front of you. Most engineers are familiar with failure modes and effects analysis (FMEA), a technique for improving machinery and equipment reliability by analyzing its functional requirements, failure modes and effects, and then taking appropriate action better manage those potential failures. However, in using these principles, this book does not focus on a given machine and its failure modes, but rather focuses on the business, specifically analyzing a production line or process at an operating to determine where the major business opportunities are relative to the gross profit associated with improved production, or reducing any extraordinary costs. In applying these principles at a business level, an element of the business is reviewed, such as a production line, defining a functional failure as anything which results in a production loss from ideal, or in extraordinary costs beyond ideal. All kinds of scenarios can evolve in this analysis, many unexpectedly so, driving the business to do any number of things, depending on their specific situation. So, the purpose of this book is to illustrate the methodology, and then provide numerous examples of how the technique can be applied in varying circumstances, helping you prioritize your efforts.