Effectiveness of Failure Mode and Effect Analysis (FMEA) Method: An Application in a Mattress Factory

In today's competitive environment companies use a variety of quality control methods to increase product quality and transparency, but selecting methods that are consistent with their principles may put additional power for sustainable development and profit. FMEA is one of the easiest and effective risk assessment method that aims to eliminate or prevent the errors and failures which may occur in the future. This method can be very effective when combining with different efficiency measurement methods. In this research FMEA is implemented to Bonnell-spring orthopedic mattress production factory to identify potential failure modes and find recommended solutions to increase customer satisfaction and construct a better workplace. Numerous calculations applied in order to arrange different failure modes and calculate their efficiencies using Data Envelopment Analysis (DEA) method. It has been found that the FMEA itself can be insufficient as using aggregated FMEA and calculating the efficiency by DEA changed the importance of some failures. DEA based FMEA was the first corresponding research related to mattress production industry. Keywords: FMEA, DEA, DEA based FMEA