Risk-Based Performance Optimization of Mozzarella Cheese Processing Using Expert Judgement – Preference Selection Index (PSI) Model

Abstract

The failures of machines in the food processing plants tend to cause lower productivity, quality decline, and increased operation costs as a result of the unplanned downtime and loss of products. The production of mozzarella cheese is extremely sensitive to the reliability of equipment since its production is a thermal-mechanical process that needs to be controlled on a regular basis. This paper introduces a combined Expert Judgement-Preference Selection Index (EJ-PSI) model to consider and prioritize risks related to machine failures in the Mozzarella cheese processing. The relevance of decision criteria to the weighted relevance of the decision criteria was assigned by quantifying and normalizing expert evaluations of ten industry experts on the basis of experience, qualification, supervisory exposure, and audit involvement. The model considers three key systems, eleven key components, and twenty-one key failure modes, thus producing ranked risk profiles to prioritize maintenance. The findings show that the Moulder, Pre-Cooking & Cooking Stretching Machine and Stretching Machine are the most important systems that determine the throughput and the severity of defects. The EJ-PSI model facilitates the predictive maintenance planning process by determining the components that need to be addressed in time to prevent possible failures. The given model proves to be highly applicable in the context of complex production settings as it allows making decisions based on risks and minimizes variability in operations.