Estudo de caso: aplicação da ferramenta FMEA no processo de fabricação de rotores de alumínio de pequeno porte

Abstract

In recent years, quality has become a fundamental theme in the industrial environment, which companies must prioritize it to remain competitive in the market and meet customer expectations. As competition intensifies and becomes increasingly complex, operational excellence and the delivery of high-quality products and services are necessary conditions for business success. Organizations are constantly seeking to improve their processes, adopt effective management practices, and implement tools and methods to enhance product quality. In this context, this study proposes the application of the quality tool FMEA – Failure Mode and Effect Analysis in the manufacturing process of small aluminum rotors of a Brazilian multinational company, aiming to identify, improve, and standardize the stages of the production process. Throughout the study, potential failure modes of two departments of the company in question were identified, as well as the prioritization of risk of failures using pre-established criteria. The analysis resulted in the identification of the most critical causes of the system, highlighting the process stages that require priority interventions for problem mitigation, such as, sheets with excessive oiliness, damage to the rotors during the pressing process, deterioration of radial runout after thermal shock, and operational failures. Thus, strategies were proposed including improvements in the selection procedures of the raw material of the sheets used in the manufacture of the rotors, norm changes, tests and studies for the validation of new products to be used, and operator training. These strategies contributed not only to avoiding failures and reducing costs, with a possible reduction of the identified and prioritized faults by approximately 5%, but also to promoting a culture of operational excellence and ensuring customer satisfaction.