Process Failure Modes and Effects Analysis (PFMEA) and Improvements on Valve Seizure Issue in Engine Assembly

This study analyzes and improves defects encountered in the production processes of internal combustion engines in an engine assembly plant. Process Failure Modes and Effects Analysis (PFMEA) was utilized to detect, assess, and minimize these defects. To enhance its effectiveness, 6M analysis, Ishikawa diagrams, root cause analysis, and statistical process control (SPC) techniques were applied. The research primarily focuses on the valve seizure issue in the cylinder head assembly process, identifying root causes and implementing preventive and corrective actions. As a result, critical defects were significantly reduced, process efficiency improved, and annual defect-related costs decreased. This study provides valuable insights into quality management and continuous improvement in the automotive industry. The systematic application of PFMEA enables proactive error detection, better process control, and enhanced quality standards. Findings contribute to developing a structured framework for quality management in similar manufacturing environments.