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Original research
MULTI-ATTRIBUTE RISK PRIORITIZATION OF INJECTION-MOULDING DEFECTS USING DMAIC, FMEA, MAFMA AND FUZZY AHPPages 57-66
Abstract:
This study investigates how failure-prioritisation decisions change when conventional Failure Mode and Effects Analysis (FMEA) is extended with Multi-Attribute Failure Mode Analysis (MAFMA) and fuzzy Analytic Hierarchy Process (FAHP) within a DMAIC quality-improvement framework. The industrial case concerns an automotive injection-moulding process that produced 85,016 units, of which 5,131 were defective (6.04%); short shot accounted for 51.4% of recorded defects. Conventional FMEA ranked operator/SOP-related failure first (RPN 100), whereas MAFMA-FAHP ranked inadequate mould design first (priority 0.47). Independent AHP checks confirmed acceptable consistency for the criterion and expected-cost pairwise matrices (CR=0.070 and 0.089). Sensitivity analysis showed that mould design remained the top-ranked cause under equal weights, ±20% changes in expected-cost weight, and a no-cost scenario. The findings show that explicit weighting and economic consequence can materially alter improvement priorities and that robustness checks should accompany multi-attribute risk ranking.
Keywords:
DMAIC, failure mode and effects analysis, fuzzy AHP, injection moulding, MAFMA, quality improvement, risk prioritisation, Six Sigma.
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Emi Rusmiati,
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