Risk prioritization using a modified FMEA analysis in industry 4.0

Abstract

To assess the reliability of production systems, a Failure Mode and Effects Analysis (FMEA) is usually performed to determine how reliable a system is in its entirety. In order to ensure smooth production operations and timely delivery of orders, it is necessary to ensure continuity of operations without failure and interruption. Industry 4.0 (I4.0) can provide so many benefits, but it also introduces new challenges because of its technical components such as sensors and actuators. In this paper, we propose an FMEA model and structure quantitative risk assessment metrics for a yogurt-filling system in an I4.0 environment. We use the risk priority number (RPN), which is usually a product of three factors: severity (S), occurrence (O), and detection (D) ratings. In this study, we use also a fourth factor, namely, dependency (D2). We compare RPN scores for traditional components and I4.0 components. The application method of the FMEA model was presented in detail, and its practicality was verified and demonstrated. To get valid results, a team of experts was utilized. Then Pareto method was used together with the FEMA approach to prioritize the risks that need more attention. After that, risk prevention steps were introduced. Results showed that four components are the most important ones. Results also showed that some of the components of I4.0, such as proximity sensors and color detection sensors were found with the largest priority. A better performance was achieved following the enhancements suggested by the experts' team. A reduction in RPN of 55% has been achieved by implementing the upgrades, indicating an increase in system reliability.