Integration of modified FMEA approach with Industry 4.0 technologies to improve reliability of lean systems

Many organisations are using lean tools with Industry 4.0 technology these days to enhance the sustainability of their lean manufacturing systems. This article contributes by combining a lean tool (modified FMEA) with Industry 4.0 technologies to improve the dependability of lean systems. Under the four lean subsystems of personnel, equipment, materials, and schedules, a redesigned FMEA framework incorporating Industry 4.0 technologies is proposed. From the mapping of lean wastes, inventory accounts for 39% of total waste, overproduction accounts for 23% of total waste, defects account for 22% of total waste, non-utilised talent accounts for 16% of total waste based on RAV calculation from modified FMEA table. Also based on RPN calculation from the modified FMEA table, Inventory accounts for 45% of total waste, overproduction accounts for 23%, of total waste, defects account for 19% of total waste, non-utilised talent accounts for 13% of total waste. © 2024 Inderscience Enterprises Ltd.