Fuzzy risk priority number assessment for solar gel battery manufacturing defects

•Description of solar gel battery manufacturing process.•Determination of the failure modes of battery manufacturing, their causes and effects•Application of Fuzzy logic method using linguistic terms for the inputs factors.•Comparison between the proposed fuzzy FMECA with traditional FMECA.•Implementation of Pareto Chart to initiates corrective actions for critical causes. The manufacturing quality of the solar gel battery has a weighty impact on its performances as well as its available rated capacity and lifetime. It is possible to achieve many improvements of battery quality by making attention to the critical causes of manufacturing process defect. The aim of this paper is the critical assessment of the manufacturing process defects of the solar gel battery using a novel approach based on a combination of Failure Mode and Effect Analysis (FMEA), fuzzy logic method and Pareto chart. FMEA is performed for the manufacturing process with the aim of identifying the various failure modes, their causes and effects. The implementation of the fuzzy logic method for the input factors: Occurrence (O), Severity (S) and Non-detection (ND), then these factors are related to reach Fuzzy Risk Priority Number (FRPN). A comparative study is done to assess the validity and efficiency of fuzzy FMECA versus the traditional Failure Mode, Effects and Criticality Analysis (FMECA). This study is completed by developing Pareto chart to highlight the most important causes and suggest some corrective actions. The results prove that the proposed approach can efficiently assess the manufacturing process defects of solar gel battery.