Deployment of an FMEA-Integrated Framework to Improve Operational Performance in Semiconductor Manufacturing: A Case Study

The failure mode effect analysis (FMEA) aims to strengthen the operational performance of a process of a product. However, current FMEA practice does not quantify the achievement in operational performances. Risk priority number (RPN), the only success indicator of FMEA, is independent of operational performance monitoring. Thus, the capability of FMEA to strengthen operational performance may be ineffectual unless it demonstrates a quantifiable improvement in operational performance. This study offered guidelines for manufacturing industry to quantify the operational performance within the FMEA methodology by operational performance indicator (OPI). In tandem with RPN, the OPI in FMEA ascertains the priority set by RPN and defines more refined priority than RPN. Design for manufacturing and assembly (DFMA) and Poka-yoke provide systematic guidelines for developing corrective actions for eliminating or reducing the occurrence of failure while strengthening current control to prevent the delivery of any non-conformance to customers. Application of the new FMEA-based integrated framework in a semiconductor manufacturer in Malaysia demonstrated that 69.2% improved the overall equipment efficiency (OEE).