Extraction and analysis of production process Failures using PFMEA logic (case study: Kurdistan Sugar factory)

The purpose of this research is to identify possible failures modes in the process of producing Kurdistan sugar factory. In this research, firstly, the Process map of the production process by using the IDEF0 modeling logic was extracted accurately in order to schematically analyze all the aspects and processes of sugar production from raw sugar. Then, in the form of teamwork and at various expert meetings, 49 major and potential failures were identified in all processes and activities of the sugar production process. In the following sessions, the failure severity, the probability of occurrence of failures and the probability of error detection were determined. Using the RPN (risk priority number) was extracted for each failure. In the following, the root causes of the 24 priority failures were determined by FTA, and due to the causes of the errors, suitable solutions to reduce the effects of failures were documented. Finally, the origins of process failures were analyzed.