Risk Analysis and Process Optimization in Toy Manufacturing Using FMEA, Six Sigma, and Statistical Process Control
Keywords:
Failure Mode and Effects Analysis (FMEA), Six Sigma, Statistical Process Control (SPC), Toy Manufacturing, Process Variability, Lean Manufacturing.Abstract
This study presents a structured framework for risk evaluation and mitigation in the manufacturing process of Hot Wheels toy cars using Failure Mode and Effects Analysis (FMEA), Statistical Process Control (SPC), and Six Sigma methodologies. The multi-stage manufacturing process, including die casting, plastic molding, painting, assembly, wheel fitting, and packaging, is systematically analyzed to identify potential failure modes and associated risks. Risk prioritization is performed using the Risk Priority Number (RPN), based on severity, occurrence, and detection parameters. The analysis reveals that die casting (RPN = 240), painting (RPN = 216), and wheel fitting (RPN = 210) collectively contribute approximately 75% of total risk exposure, indicating critical process stages. Root cause analysis identifies process variability (38–42%) and human error (22–28%) as the primary contributors to failures, with high-risk categories accounting for nearly 66% of total risks. The implementation of SPC is shown to reduce process variability by 25–35%, while Six Sigma methodologies target defect reduction to near-zero levels (3.4 DPMO). The integration of these approaches, supported by lean manufacturing principles, enhances process stability, product quality, and operational efficiency. The study demonstrates that a targeted and integrated risk management approach can significantly improve reliability and performance in toy manufacturing systems.
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Copyright (c) 2026 SHREEYASH MHATRE, AVINASH SOMATKAR (Author)
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