The purpose of this paper is to propose a methodology to reduce the potential risk of failures in high‐volume manufacturing.
The research documented here represents an even balance of theoretical and practical development, with validation of the methodology – referred to as integrated risk minimisation (IRM).
The success of the IRM is measured in terms of reduced defect rates, through either prediction or earlier detection of defects. The combination of an inline design and immediate operator feedback on all detected defects was a critical design element.
The electroplating process was chosen as a suitable case study to provide the platform from which the IRM could be developed and tested. Implementation into industry has generated the proof to support the IRM as a methodology that can successfully reduce potential risks in high‐volume manufacturing.
In a unique approach, failure modes and effects analysis is built into the IRM methodology, thus establishing a “closed loop” process. The IRM methodology is suitably generic, to allow the achievement of similar results for any high‐volume process.
