FAILURE MODE AND EFFECTS ANALYSIS AS A PROACTIVE TOOL WITHIN A WORLD CLASS MANUFACTURING FRAMEWORK: THE TETRA PAK CASE STUDY

This thesis explores the application of Failure Mode and Effects Analysis (FMEA) as a proactive tool within the World Class Manufacturing (WCM) framework, focusing on its integration into safety management practices. The study is based on a case analysis conducted at Tetra Pak’s Rubiera converting factory, a leading site for packaging material production. The research begins by outlining Tetra Pak’s organizational context, followed by an overview of the manufacturing process. The second part introduces the WCM philosophy, a structured system for continuous improvement, and emphasis is placed on the Safety & Health pillar, which aims to eradicate workplace accidents and occupational illnesses through risk analysis, preventive measures, and cultural engagement. The core of the thesis examines the FMEA methodology, its historical evolution and its role in anticipating failures before they occur. The research details the FMEA process and applies this methodology to a safety risk assessment, prioritizing risk categories based on historical data and strategic safety objectives. This case study demonstrates that integrating FMEA into WCM practices strengthens operational reliability, reduces costs, and promotes a proactive approach to workplace safety. Beyond technical improvements, the methodology drives cultural transformation by embedding risk awareness into daily routines and encouraging cross-functional collaboration.