Utilising FMEA to improve the reliability of packaging equipment : the case of packaging equipment at Pepsico Durban

Abstract

The study aimed to enhance the reliability of packaging equipment at PepsiCo Durban using Failure Mode and Effects Analysis (FMEA). The focus is on mitigating unplanned stoppages in the packaging hall, which has led to significant waste of potato chips due to equipment failures. The research addresses the need for proactive maintenance strategies within the Fast-Moving Consumer Goods (FMCG) industry, emphasising the importance of sustainable practices in manufacturing. The methodology used a mixed-method approach, including document analysis of maintenance records, thematic analysis to identify patterns and critical failure modes and interviews with the maintenance team. The study evaluated the implementation of audit findings from ISO 9001 and the PepsiCo Europe Maintenance Methodology (PEMM). By integrating FMEA within the existing quality management framework, the research developed a comprehensive strategy to improve equipment reliability and reduce operational inefficiencies. This approach aligns with Sustainable Development Goals, particularly those related to responsible consumption, climate action, and life on land. Overall, the study provides insights into improving operational sustainability using FMEA in enhancing packaging process reliability, ultimately contributing to the reduction of packaging waste and promoting environmental stewardship. The study identified critical failure modes in packaging equipment, particularly mechanical wear, lubrication deficiencies, and inadequate preventive maintenance, as primary contributors to unplanned downtime at PepsiCo Durban. Through the application of FMEA, the research uncovered root causes such as ineffective maintenance scheduling, insufficient operator and engineering personnel training, and poor documentation practices. High-risk equipment, including case packers and sealers, was prioritised using Risk Priority Numbers (RPNs). The study further developed targeted strategies to improve equipment reliability, including enhanced preventive maintenance planning, operator and engineering personnel upskilling, and improved spare parts and data management. The integration of FMEA into the existing quality management framework proved effective in reducing equipment failure, minimising waste, and supporting sustainable operational improvements aligned with PepsiCo’s environmental and efficiency goals.