Extracting Manufacturing Process Map in the Form of the IDEF Model Prerequisite for the Implementation of PFMEA in the Sugar Industry

The purpose of this research is to demonstrate the importance of extracting business process mappings as a prerequisite for the implementation of the PFMEA (Process Failure Mode and Effect Analysis). In the first stage, 30 production process failures were extracted in the meetings with factory managers. Then, a team was formed by the presence of process owners, and with the help of the project team, the production process map was drawn up according to the IDEF0 standard. In the next step, for the second time, potential failures were extracted according to the production process map. This time, 49 failures in the production process with the potential sources of failures were identified. The results of the study showed that by extraction of the production process map, more failures in the production process would be detectable. In fact, extraction of the process map is a prerequisite for the implementation of the PFMEA. In this research, in order to better describe the steps taken, all extracted processes are schematically illustrated in accordance with the IDEF0 Modeling Standard, so that other sugar-producing companies can also use them to implement the PFMEA. The innovative aspect of this research is to extract the production process failures before and after extracting the process map and compare them with each other.