Critical Analysis of Chemical Machining Setup Design using FMECA

The Failure Mode, Effects, and Criticality Analysis (FMECA) approach enabled the prioritization of failure modes and implementation of targeted interventions, resulting in improved reliability, consistent machining quality, and process efficiency. This paper conducts a critical analysis of a chemical machining setup design using FMECA. The chemical machining is a material removal process where key parameters such as chemical concentration, temperature, and stirring play pivotal roles in product quality. The study identifies critical subsystems, including temperature monitoring, the main controller, and the stirrer, which are integral to maintaining process stability and quality. Quantitative assessment using the Risk Priority Number (RPN) revealed that temperature monitoring contributed approximately 47% to the overall system risk, highlighting its criticality. Corrective actions, including enhanced sensors, optimized stirring mechanisms, and improved insulation, significantly reduced RPN values. This analysis underscores the importance of robust design, precise parameter control, and predictive maintenance in chemical machining setups.