Failure Mode Effects and Criticality Analysis (FMECA) as a quality tool to plan improvements in Ultrasonic Mould Cleaning Systems

Inside the complex process used for tire production, ultrasonic cleaning treatment probably represents the best solution to preserve the functionality of tire moulds, by removing residuals from moulds and keeping an unaltered quality for their surfaces. Ultrasonic Mould Cleaning Systems (UMCS) is, however, a complicated technology that combines ultrasonic waves, high temperature and a succession of acid and basic attacks. At the same time, an UMCS plant, as part of a long productive chain, has to guarantee the highest productivity reducing failures and maintenances. This article describes the use of Failure Mode Effects and Criticality Analysis (FMECA) as a methodology for improving quality in cleaning process. In particular, FMECA was utilized to identify potential defects in the original plant design, to recognize the inner causes of some failures actually occurred during operations and, finally, to suggest definitive re-design actions. Changes were implemented and the new UMCS offers a better quality in term of higher availability and productivity.