Proceedings of the

The 33rd European Safety and Reliability Conference (ESREL 2023)
3 – 8 September 2023, Southampton, UK

Risk Analysis in the Manufacturing and Transportation of Precast Concrete using PFMEA

Saulo Alessandro Marinho de Freitasa and José Cristiano Pereirab

Universidade Católica de Petrópolis-UCP, Brazil.


The study analyzes micro and small enterprises in Brazil, which represent 93% of all active companies, employ 62% of the workforce, and contribute 27% of the Gross Domestic Product (GDP). It was observed that these companies, especially one in the construction sector in the state of Rio de Janeiro, suffer from a lack of fault detection processes and high rework rates. The study sought to identify risks and implement responses to improve material preparation, manufacturing, and transportation of concrete parts. It used tools such as Process Mapping, PFMEA, and Porter's 5 Forces Analysis, where internal documentation and scientific literature were consulted. As a result, the critical steps of the processes were mapped, failure modes were identified, and actions were defined for risks with high RPN (Risk Prioritization Level). The actions resulted in process improvement, failure and cost reduction, and increased customer satisfaction. Although focused on one company, the study can be applied to other precast and precast concrete companies, impacting the practice and thinking of professionals in the industry.

Keywords: Failure mode and effect analysis, Transportation, Precast, Precast, Concrete artifacts, Cracking, Hoisting, Pre-Slabs, Solid slabs, Risk.

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