Risk Management With Parameter Modeling by FMEA: a Case Study in a Large Printing Plant
Authors: Piloto Kamile Jeane Silva Nascimento , Lima Gilson Brito Alves , Severino Mauro Moura 
Published: June 2024

Objective: The objective of this study is to identify, analyze and control the risks to occupational health and safety present in the operation of a printing machine, through FMEA and modeling in Excel VBA of the parameters severity, occurrence and detectability, with the aim of identifying the failure modes that must be treated as a priority.

Theoretical Framework: FMEA is widely used in the identification and analysis of potential or known failures in processes, therefore enabling decision-making support. To be most effective, FMEA must be developed by a team. With the aim of adjusting points for improving the application of the technique, it is proposed to combine FMEA with other existing analysis and multi-criteria methods. In this research, FMEA is used in conjunction with Excel VBA programming that allows multiplication within ranges of randomly generated values, using the histogram to prioritize the RPN.

Method: The methodology adopted for this research involves defining, based on the criticality of the printing machines, the machine that will be the object of study to develop and apply a methodology for occupational health and safety through the application of FMEA by focal group, composed of eight professionals, and modeling of RPN parameters to prioritize risk mitigation measures. The classification of the research regarding its nature is applied; as for the nature of the data, it is quali-quantitative; as for the purpose, it is exploratory; As for the delimitation, it is non-experimental. In the case study, the following data collection methods were used: interviews with printing workers, observations and application of the FMEA form (from ISO 31010).

Results and Discussion: The results obtained revealed that the risks present in the operation include: Electric shock; neck/spine pain; limb fracture; cuts; abrasions, among others. The modeling carried out through programming in Excel VBA made it possible to multiply, within the respective ranges of intervals, random numbers obtained for the variables Si, Oi and Di, obtaining 200 RPN results and Si x Oi products. The failure mode which must be addressed, as a priority, concerns the “Descending of the rocker arm with the hand(s) positioned in the field of action” on the Melmaq machine model 800 TM it is possible to mitigate the most significant risk by installing sensor to detect the presence of the hand and rocker arm pressure adjustment system. Throughout the research, some difficulties were encountered, with emphasis on the challenge of finding professionals who had knowledge about machine operation, work safety, as well as the FMEA risk management technique, and who were willing to participate in the research.

Research Implications: Practically, the research directly contributed to risk management in the operation of the paper shearing machine at the printing company under study. Theoretically, the research develops and applies a methodology that utilizes the FMEA technique supported by VBA modeling in Excel for the parameters of severity, occurrence, and detectability.

Originality/Value: The search in the Scopus and Web of Science databases, during the conducting of the research, revealed a lack of publications in the area of occupational safety risk management in printing machines using FMEA.