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MRC Delivers Failure Modes Effects Analysis (FMEA) Trainingto Mitsubishi Chemical Group, Increasing Successful Installation Rate
“We turn to MRC for many of our training needs. Their instructors are knowledgeable, can relate to manufacturers, and show us how to implement training in our processes.”
– Matt Seeuwen, NA Continuous Improvement Manager
Mitsubishi Chemical Group’s (MCG’s) Engineered Shapes and Solutions division, based in Reading, Pennsylvania, sought to initiate Failure Modes and Effects Analysis (FMEA) at the request of a regional Director of Manufacturing. Specifically, in order to prevent future equipment failures—and in light of recent failures at other regional facilities—the company hoped to pursue training on Design FMEA (DFMEA) and Process FMEA (PFMEA) methodologies.
“There was a need to build more robust project management and equipment selection processes,” says Alan Holbrook, MCG’s NA Engineering Manager. “FMEA helps us identify potential losses and failure modes to improve project results.”
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Solution
With a proven ability to help MCG meet performance, profitability, and leadership development goals, the company turned again to MRC for the FMEA training initiative.
FMEA identifies overall potential failure points within a process and its associated equipment, scoring those points and assigning each a Risk Priority Number to quantify the potential severity and likelihood/frequency of occurrence.
“In other words,” says Matt Seeuwen, MCG’s NA Continuous Improvement Manager, “the scores help you prioritize the risk and address those with the largest impact first.”
MRC’s trainer began with a facility walkthrough to better understand the operation, help the team decide which systems to include in the assessment, and tailor the training for the situation on the ground. Training was held on site at four MCG locations, with each hosting multiple sessions.
“We staged the training across multiple sessions in order to learn and apply,” says Holbrook. “It wasn’t all classroom instruction. We preselected equipment and processes we thought were at higher risk, then incorporated the analysis into the training. That also made it possible to carry out routine production work between the sessions, as we determined necessary.”
As a risk mitigation tool, FMEA makes it possible to effectively quantify and minimize the risk associated with processes and equipment that could be problematic. In addition to multiple rounds of Lean Green- and Black-Belt training, Seeuwen says their MRC engagement enables MCG to expand their project management capabilities.
Results
- Process improvements – Significant increase in fully successful installations post FMEA integration into relevant processes
- Increased Profitability – Identifying and correcting failure modes in existing processes and equipment improved throughput; and
- Increased Savings – Nine Black Belt training projects completed in 2022 alone—following a similar learn-and-do approach—have delivered measurable financial benefit and savings.
To learn more about Mitsubishi Chemical Group, Reading, PA please visit their website at www.mcam.com/en