Framework of integrated-decision support system for risk identification and mitigation in manufacturing industry: aiming zero-defect manufacturing

Risk management in manufacturing industry has become a trend to reach zero-defect manufacturing (ZDM), so there is a need to fill a gap by developing a decision-making mechanism for product-process related risks. The proposed decision support system (DSS) framework allows integration of product design and manufacturing process related risk identification with mitigation (first novelty) in metallic plates cutting/separating platform as a case study. Delphi technique (two-round) was employed to shortlist 25 identified risks along with their 33 mitigation strategies, followed by an improved risk exposure method to analyse individual risks in terms of their probability and impact with respect to time, cost, and quality (second novelty). Decision-making trial and evaluation laboratory (DEMATEL) analysis was adopted to prioritize based on interaction among risks. A comparison between risk analysis and prioritization results aids the decision maker in opting for a DSS based on ranking of either 'individual' or 'interacting' risks. The knowledge-driven integrated-DSS expects to help the shop floor operator make better decisions by providing effective and efficient solutions to counter the risks. The proposed model can be considered as one step closer to the data-driven ZDM concept as it will minimize time and cost, ultimately enhance quality in a manufacturing setup.