Statistical Evaluation of Failure Mode Drivers via the 5M+1E Framework for Enhanced Reliability Control in Automotive Interior Manufacturing

Authors:
Open Access
Publisher website
Google Scholar
Abstract
A comprehensive statistical analysis was conducted to investigate the causes and prioritization of failure modes within a production line manufacturing leather covers for automotive interiors. The study was grounded in a Process Failure Mode and Effects Analysis (PFMEA), with a dual emphasis on evaluating the traditional Risk Priority Number (RPN) approach and the more contemporary Action Priority (AP) methodology, which has been increasingly adopted to enhance risk assessment sensitivity. Failure modes were classified and prioritized using both approaches, revealing notable differences in the ranking outcomes. To further elucidate the underlying contributors to these failure modes, causal factors were systematically categorized in accordance with the 5M+1E framework—Man, Machine, Method, Material, Measurement, and Environment—commonly employed in quality and reliability engineering. A cause-and-effect diagram was constructed to visualize the distribution of root causes across these categories. Descriptive statistics and correlation analyses were employed to quantify the relationship between each category and the prioritized failure modes. Particular attention was paid to examining the interdependencies among the core PFMEA parameters—Severity, Occurrence, and Detection—in order to determine their respective contributions to the variability in failure mode rankings. It was found that Severity exerted the most substantial influence on the prioritization outcomes under the AP model, while Occurrence was more dominant when the RPN method was applied. These findings suggest that the choice of prioritization method significantly alters the interpretation of risk and resource allocation for corrective actions. The integration of 5M+1E categorization with PFMEA metrics offers a structured pathway to enhance the diagnostic capability of reliability assessments and improve decision-making in failure prevention strategies. This approach is proposed as a more robust alternative to traditional analysis, enabling more precise targeting of corrective and preventive measures in high-precision manufacturing environments.

This publication has 18 references indexed in Scilit: