• Dr. RajiRajan
• Dr. V.R.Pramod

Traditional Failure Mode and Effect Analysis (FMEA), while widely used for quality assurance, often struggles in real-time industrial settings due to complexity, limited inclusivity, and static assessments. Total Failure Mode and Effect Analysis (TFMEA) offers a streamlined, participative approach, enhancing employee involvement and actionable improvements. This study reports the application of TFMEA in a government-owned casting unit in Kerala, India, aiming for zero-defect manufacturing by addressing systemic inefficiencies. A mixed-method approach involving interviews, surveys, fishbone diagrams, and structured discussions was used to identify and rectify critical failure modes in the conventional casting. Interventions included forming cross-functional teams, implementing visual management, and centralized documentation. Key process improvements targeted melting temperature control, pattern tapering, mould compaction, and gating system design. Results showed significant gains in defect tracking, rejection rate reduction, and team coordination, reinforcing TFMEA’s effectiveness as a dynamic, employee-driven quality framework.

TFMEA, casting industry, quality improvement, zero failure, ISM, FMEA, TQM, and Kerala.

"Implementation of TFMEA for Zero Defect Strategy in Conventional Casting: A Case Study from Kerala, India", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 5, page no.j879-j882, May-2025, Available :http://www.jetir.org/papers/JETIR2505A80.pdf

"Implementation of TFMEA for Zero Defect Strategy in Conventional Casting: A Case Study from Kerala, India", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 5, page no. ppj879-j882, May-2025, Available at : http://www.jetir.org/papers/JETIR2505A80.pdf