Quantitative Risk Management and Defect Mitigation in Plastic Injection Molding using Failure Mode and Effects Analysis
DOI:
https://doi.org/10.60112/erc.v6.i3.905Palabras clave:
failure mode and effects analysis, injection molding, defect mitigation, risk priority number, automotive sectorResumen
Although Failure Mode and Effects Analysis (FMEA) is a well-established quality tool, few published case studies document its systematic, before-after application to a criticality-ranked fleet of production tooling paired with a traceability scheme for periodic revalidation; this study addresses that gap. It analyzes defect mitigation in plastic injection molding in the automotive sector, at an organization with a high incidence of flash, bubbles, and short shots that were driving up scrap rates and hurting operational efficiency. FMEA was applied systematically to quantify and reduce the criticality of these deviations, using an explicit criticality index to select the 10 highest-impact molds from a fleet of 200 and scoring severity, occurrence, and detection to obtain the Risk Priority Number (RPN) for each failure mode. Interventions included parameterizing injection variables, thermodynamic optimization of the molds, pressure sensors, and standardized operating procedures. RPN values for the most critical defects dropped substantially, which is consistent with a more reliable process. Overall, FMEA proved effective for controlling variability and managing risk in the manufacturing of automotive plastic components, offering a replicable model for supplier organizations aligning with IATF 16949 risk-management requirements.
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Derechos de autor 2026 Josué Antonio Cruz Cruz, Erick Uriel Morales Cruz , Estella María Esparza Zúñiga , Demetrio Fuentes Hernández , Jaime Garnica González
Esta obra está bajo una licencia internacional Creative Commons Atribución 4.0.
