Design Failure Mode And Effects Analysis Research Articles

Combining Improved DFMEA with Knowledge Graph for Component Risk Analysis of Complex Products

With the development of information technology in manufacturing, product lifecycle iteration is accelerating. Efficiently analyzing and identifying component risks is important to ensure the reliability of products. This paper proposes a new method that combines improved design failure mode and effect analysis (DFMEA) with the knowledge graph for component risk analysis of complex products. A risk evaluation knowledge graph is built for the risk identification and knowledge provision in the process of DFMEA. Graph analysis is used to identify to-be-evaluated objectives based on historical maintenance data, which helps designers avoid the heavy task of identification. The graph matrix of the historical evaluations is used to calculate the comprehensive weights. A Dempster-Shafer (DS) evidence fusion method based on comprehensive weight evaluation information is proposed for the effective fusion of evaluation evidence. As an alternative to the exact risk ranking, we offer a risk trade-off VIKOR (VIseKriterijumska Optimizacija I Kompromisno Resenje) method for components classification that classifies components into different risk classes for different risk treatment measures. Finally, the proposed method is validated using a tunnel boring machine as an example, and comparison and sensitivity analyses are performed to demonstrate that the risk value shows a consistent and stable change with expert evaluation.

Implementing Failure Mode & Effect Analysis(FMEA) on Framework Structure

Abstract: The Failure modes and effects analysis (FMEA) is one of the most practical design tools implemented in the product design to analyze the possible failures and to improve the design. The use of FMEA is diversified, and different approaches are proposed by various organizations and researchers from one application to another. The question is how to use the features of FMEA along with the design process. This research focuses on different types of FMEA in the design process, which is considered as the mapping between customer requirements, design components, and product functions. These three elements of design are the foundation of the integration model proposed in this research. The objective of this research is to understand an integrated approach of FMEA in the design process. Significantly, an integration framework is developed to integrate the design process and FMEA. Then, a step-by-step FMEA-facilitated design process is proposed to apply FMEA along with the design process. The analysis should always be started by someone listing the functions that the design needs to fulfil. Functions are the starting point of a well done FMEA, and using functions as baseline provides the best yield of an FMEA. After all, a design is only one possible solution to perform functions that need to be fulfilled. This way an FMEA can be done on concept designs as well as detail designs, on hardware as well as software, and no matter how complex the design.

DECISION ANALYSIS FOR OPTIMAL CONCEPTUAL DESIGN OF CONCURRENT BRAKE ACTUATOR

Enhanced capabilities and customization in designs demand a thorough conceptual design phase for products or equipment. To ensure favorable outcomes, a comprehensive analysis of multiple design concepts is vital. This paper aims to conduct a decision analysis to determine the most suitable design for a concurrent brake actuator (CBA) among a range of alternative design concepts. It presents the development of the conceptual design of the CBA mechanism, which serves as a foundational mechanism design for future CBA development. Four mechanism design concepts were generated by utilizing the expanding curvature contour design, linear contour design, tilted position linear slope, and the nonlinear radius profile of the cam roller. The assessment of potential failures in the CBA concept design was performed by employing the risk priority number (RPN) within the framework of Design Failure Mode and Effects Analysis (DFMEA). The data obtained from DFMEA was utilized to conduct thorough analyses of motion and stress performance for each conceptual design using commercial software. Subsequently, the most optimal concept design for the CBA was chosen. This decision was reached by selecting the CBA concept design that achieved the highest score during the evaluation process, which employed a weighted decision matrix. According to the findings, the optimal CBA concept design was determined to be CBA Design B with the highest total score of 102 based on an RPN score is 32 and maximum stress of 3.647 x 104 N/m2. Its expanding linear contour design effectively distributes nonlinear brake force while minimizing failure risk, forming the foundational framework for future CBA development.

Enhancing the dynamic performance of proton exchange membrane fuel cells through two-phase flow experimental investigation

Efficient water transfer is crucial for enhancing the rapid response and durability of proton exchange membrane fuel cells (PEMFCs). In this paper, ex situ observation experiments and in situ dynamic performance tests of fuel cells are conducted and correlated with each other by two-phase flow pressure drop. The experimental results show that slug flow within the cathode gas flow channels (GFCs) is unfavorable to mass transfer and results in loading failure under high current densities, as identified in Design Failure Mode and Effects Analysis (DFMEA). However, slug flow in GFCs of PEMFCs can be converted into film flow by reducing the hydraulic diameter of GFC, increasing the air stoichiometry ratio, and extending the loading resistance time to an appropriate value. This facilitates a successful and efficient load change process of PEMFCs under high current densities. This study provides a methodology, combines ex situ observation and in situ evaluations, identifying potential risks, which can shed light on improving the dynamic performance and development process of PEMFCs.

Overview of Failure Mode and Effects Analysis (FMEA): A Patient Safety Tool.

Overview of Failure Mode and Effects Analysis (FMEA): A Patient Safety Tool.

Penerapan DFMEA pada Perancangan Produk Casing Lampu Berbahan Dasar Bambu

This research aims to discover the higest impact of product failures and determine the proper of solution. Design FMEA is a method to anticipate failure during the design stage by identifying all of the possible failures in a design or manufacturing process. This studi conducted in a micro, small and medium-sized enterprises (SMEs). KIM is a small company that produce handycraft product made from bamboo plants, one of the featured product is lamp casing. Any of customers complain encourage the company to make new product design and look for the cause of the problem and risk. The results of this research are obtained 5 components of lamp casing with the highest level of risk. An Improvement was carried out entirely by using a repair priority scale according to the sequence of failure modes with the highest risk of damage.

Design and numerical simulation of power operated pipe bin structure

In the proposed work, an innovative design of pipe bin structure is presented to address the problems in the conventional design of pipe bins. The designed structure is used to accommodate drill pipes ranging to 65-foot with enough structural integrity to hold a weight of 45 tons, including the 14.25 tons self-weight of the Pipe bin structure. Further, ANSYS software is used to perform a numerical simulation to identify potential design problems by examining the effects of various levels of failures on the structure. After Design Failure Mode and Effects Analysis (DFMEA) is carried out concurrently during the initial design stage. These potential design problems are identified by examining the effects of various levels of failures on the structure. The improved design shows a decrease of 83.33% in RPN, making it 200 from 240. The proposed design improves the general efficiency. Further, ANSYS software is used to verify the improved design.

A competent top down approach methodology for design and development of commercial vehicle box type exhaust after treatment system

The exhaust after-treatment system product designand developments together play a major role in driving commercialization and growth in theBS-VI commercial vehicle manufacturing sector. Accordingly, for manufacturers to capitalise on existing and up-coming market opportunities, product design and development strategies based on expanding customers’ necessities as well as market-specific challenges are a must. Though the after treatment system design is derived from EURO-VI, it cannot be implemented into BS-VI. A certain level of technology can only be transmitted to the Indian market CV applications. Accordingly, several market-specific challenges, like India's specific vehicle application as well as road-load conditions, are yet to be demarcated. Nevertheless, significant design requirements for meeting the OBD-2023 related to performance as well as emission targets for BS-VI after-treatment systems (ATS) must be considered without compromising the quality of the ATS systems due to CV (commercial vehicle) cost-sensitiveness and competitiveness. Moreover, for this box type exhaust after-treatment system design, top-down approaches are elaborated considering necessities like performance, durability, emissions, packaging, manufacturing, and assembly for service considerations. Though these are challenging requirements, a systematic design approach is essential. Based on this approach, ATS and catalyst technology concept selection are well-though and discussed. Henceforth, in order to realise the performance, quality, and durability requirements for box type after-treatment exhaust systems, quality tools such as design review, FMEA, and DVP process are incorporated and discussed. From the drop to idle test DPF material durability is well established upto 700 °C. Related to SCR, there is no concerns related to ammonia deposits and this proves robust ATS calibration.

Machine Vision Supported Quality Control Applications in Rotary Switch Production by Using Both Process FMEA and Design FMEA

Emerging in the past few decades, Industry 4.0 has wide effects over production lines with an increasing number of novel applications. These applications implement more than one of the tools of Industry 4.0. These tools include but are not limited to internet of things (IoT), big data, cloud computing, artificial intelligence, augmented reality, virtual reality, machine to machine communication (M2M), smart robot applications, etc. The aim of these efforts is mainly to acquire smarter manufacturing systems. With spreading Industry 4.0 methodologies, the role of sensors became more important to respond to new demands. One of the most important sensor types in this sense is the camera which now has wide variants in different forms. Applying machine vision algorithms via cameras grants optimization of many critical processes. In this perspective, the quality of both product and process should be handled as a key performance indicator that may be continuously enhanced for excellence. Machine vision algorithms may be adapted to check and manage quality in designated control points on the production lines. This study focuses on the control of the quality of rotary switches that are widely used in household appliances like ovens and washing machines. Rotary switches are critical components of an appliance since they direct the flow of electricity within the product. A failure in the functionality of this component directly causes the failure of the main product. Hence, the quality rate of rotary switches should be calculated in defective parts per million (dppm) units. An intense quality control procedure is required to achieve low dppm rates during production. As a real-life application, a camera system is integrated into the rotary switch production line on a selected point. Classification algorithms are developed on a cost-effective platform to perform visual quality checks of the rotary switches and qualify as “Ok” or “Defective”. The selected point ensures a high percent check of quality criteria while enabling repair of the defective parts with minor interventions. The aim of this control is to identify a defective rotary switch as soon as possible since most of the defects are irreversible once the rotary switch is totally produced or even some processes are completed. In this case, the entire product should be set apart for scrap. 
 Another originality of our study is applying both Process Failure Mode and Effect Analysis (PFMEA) and Design Failure Mode and Effect Analysis (DFMEA) together. There is almost no referenced study in the literature. 
 Benchmark comparisons are conducted upon completing the integration of the new system to the production line. As a result, enhancements in the quality, cost, and production speed parameters are achieved with a cost-effective smart system. Additional capabilities are added to the system, namely data analyzing online data feeding.

Conceptual design evaluation of concurrent brake actuator mechanism

The proper amount of braking force on both wheels is needed to optimize the braking performance and stability of the motorcycle. The braking effectiveness can be maximized by keeping the ideal nonlinear brake force distribution during braking. Thus the purpose of this research is to present a mechanism that can be accommodated as a Concurrent Brake Actuator (CBA) design to control the ideal nonlinear brake force distribution. In this paper, the conceptual design of the CBA mechanism is developed to be used as a based design for CBA development. Thus, two conceptual designs of the CBA mechanism have been generated. The proposed concept designs were evaluated based on Design Failure Mode and Effect Analysis (DFMEA) and SOLIDWORKS Motion Analysis. The potential failure of the CBA concept design was determined based on the risk priority number (RPN) in DFMEA. The information obtained from DFMEA was used in SOLIDWORKS Motion Analysis to identify stress performance analysis for each CBA conceptual design. Then, the best CBA concept design will be selected. The selection was made based on the highest score gained by the CBA concept design in qualitative evaluation. Based on the results, the fixed main body design with a tilted position linear slope in CBA Design I is potentially to actuate and distribute the nonlinear brake force to the front and rear brake with less potential of failure. Therefore, the proposed mechanism design will be used as a based mechanism design for CBA development.

A Structured Approach for Synchronising the Applications of Failure Mode and Effects Analysis

Abstract Failure Mode and Effects Analysis (FMEA) is a systematic approach for evaluating the potential failure modes in a system, and is mainly employed in three distinct tasks labelled: (1) Functional FMEA – evaluating those failures associated with product functional definition, (2) Design FMEA – analysing those failures associated with design definition and (3) Process FMEA – assessing potential failures in manufacturing and assembly processes. The literature review has shown limited works on the field of synchronising these different tasks into a working model. To address this gap, this research developed a framework for integrating these tasks of FMEAs, and then qualitatively validating the proposed framework. This research adopted a semi-structured questionnaire to collect experts’ feedback and validate the proposed framework. The t-test was then employed to evaluate the collected feedback. The findings highlight that the proposed framework is applicable and could facilitate the synchronisation of the different tasks of FMEA. This research presents a methodological approach for executing and synchronising FMEAs. Therefore, the proposed framework is practically relevant as an aid for the practitioners in catching the cascading failures and reducing the relevant impact.

Design for Reliability Through Text Mining and Optimal Product Verification and Validation Planning

Failure mode and effects analysis (FMEA) has been widely used in product design process as a reliability analysis technique. Design FMEA (DFMEA), which is used in the product development phase to identify and mitigate product risk, is one of the three application scenarios of FMEA. During the DFMEA process, verification and validation (V&V) activities are proposed to mitigate the risk of the identified potential failure modes. The V&V activities can be further planned and implemented to improve the product reliability under development. However, the DFMEA report usually contains rich text descriptions of potential failure modes and causes, and it is difficult and nonintuitive to fully understand these information for design improvements. In addition, it is also very challenging to optimize the planning of V&V activities by selecting a set of V&V activities to achieve expected reliability improvement effectiveness with the minimum resource consumption requirement. To address these two challenges, this article first proposes a method of applying text mining to the DFMEA report to obtain two types of hidden reliability information, including the classifications of failure modes/causes and the correlation between keywords. Then, a mathematical model is proposed to optimize the product V&V planning by selecting an optimal set of V&V activities. The application of the above proposed methods is illustrated through the product development of a diesel engine power generation system.

Design Failure Mode and Effect Analysis – Case Study

Design-Failure mode and effect analysis (D-FMEA) is very important tool used in industries to detect failure during design stage. D-FMEA is a technique to find out causes of failure and their effects on the performance of a system(parts) during design phase. In this paper, the D-FMEA of critical components of designed automatic tilting mechanism trolley is carried out. The critical components of automatic tilting mechanism trolley are identified and analyzed by the D-FMEA tool. This paper provides risk priority number of components of trolley. The component with higher risk priority number has higher chances of failure. The risk priority number of critical components is reduced by incorporating corrective actions. This paper provides probable causes of failure, effects of failure and corrective actions to be undertaken during design phase of Automatic tilting mechanism trolley. The D-FMEA tools helps in reducing accidents.

Design Failure Modes and Effects Analysis (DFMEA) of Self Propelled Onion Harvester (TIFAN Vehicle)

Design Failure Modes and Effects Analysis (DFMEA) of Self Propelled Onion Harvester (TIFAN Vehicle)

The use of the design FMEA method on the example of a guttering system

The use of the design FMEA method on the example of a guttering system

Design Failure Mode and Effects Analysis (DFMEA) for Automotive Safety Systems

Design Failure Mode and Effects Analysis (DFMEA) for Automotive Safety Systems

Fuzzy-analytical-hierarchy process in failure mode and effect analysis (FMEA) to identify process failure in the warehouse of a cement industry

PurposeThis paper aims to identify and reduce possible process failures occurred in warehouse.Design/methodology/approachThis research used risk analysis method FMEA combined with fuzzy-analytical hierarchy process (AHP). Design FMEA will direct the failure mode or failure of components into levels and will use it to analyze the product before it used in manufacturing processes. Design FMEA has a major point on the failure mode that caused inefficiency in the design while fuzzy-AHP used to reduce subjectivity in the weighting process.FindingsThe results show that high inventory is the dominant factor that must be controlled by the company to prevent the risk of failure processes in the warehouse, followed by the number of stocks that do not match with existing records, and misplacement of machines and/or materials.Originality/valueThis research used risk analysis method FMEA combined with fuzzy-AHP to identify and reduce the possible process failures in warehousing.

Engineering Risk of Series Production in Automotive Industry

Abstract The global objective of this paper is to analyze engineering risk of series production in Automotive Industries based on problems caused by supplied chain of products when a strong process to avoid engineering risk problems is missing. Automotive Industries Companies in Romania use just some theoretical tools like as D-FMEA (Design – Failure Mode and Effect Analysis) for engineering risk in their design products in ADAS domein. The main causes appear after the production starts and sometimes it brings the production to a halt. The risks reveal details of different levels and high risk can be caused by unforeseen challenges during of series production. On this paper, the method for engineering risk of management used is based on project management guide by Paul Roberts adapted to causes identification and risk plan.

Proposal of an analog voltmeter PCB’s design layout based on DFMEA methodology for failure reduction

With the constant demand of automotive industries for embedded electronic devices in order to employ them in vehicles that needs constant monitoring and management of their energy systems, analog voltmeters stands out in this kind of application by their measurement efficiency and driver’s assistance. This electronic device is often used for variable’s controlling in fields where requires total measurement preciosion, such as: automotive ebedded systems, process control, electrical machenary testing, electronic diagnosis and so on. The current work was designed to the development of an analog voltmeter PCB’s design layout based on DFMEA (Design Failure Mode and Effects Analysis) methodology, to avoid potential failures during design conception. The confection process of those PCB’s layouts begins with the analysis of two original circuits in AutoCAD, where the main problem verifyed was the alterations to be done in the circuits due the layer’s distribution scenario. This problem was solved through SMT components re-adjustment applying DFMEA methodology. In the application of this meyhodology, the percentage of potential failures was about to 61% to the first circuit and 38% to the second circuit. This results idicates that the application of DFMEA in PCB’s design layout is highly efficient to detect, identify and classify the risk and severity of potential failures during the project development. Keywords- Vehicle electronics, embedded systems, DFMEA, PCB design, instrumentation, failure reduction

Cost consequence of failure in failure mode and effect analysis

PurposeThe purpose of this paper is to investigate the possibility of including the cost consequence of failure in the a priori risk assessment methodology known as failure mode and effect analysis (FMEA).Design/methodology/approachA model of the standard costs that are incurred when an electronic control module in an automotive application fails in service was developed. These costs were related to the Design FMEA ranking of the level of severity of the failure mode and the probability of its occurrence. Monte Carlo simulations were conducted to establish the average costs expected for each level of severity at each level of occurrence. The results were aggregated using fuzzy utility sets into a nine-point ordinal scale of cost consequence. The criterion validity of this scale was assessed with warranty cost data derived from a case study.FindingsIt was found that the model slightly underestimated the warranty costs that accrued, but the fit could be improved with adjustments dictated by actual usage conditions.Research limitations/implicationsCost data used in the simulations were derived from government and academic surveys, analyses, and estimates of the manufacturing cost structure; and nominal costs for various quality issues experienced by Tier 2 automotive electronics supplier. Specificity is lacking. The sample size and the type of the failure modes used to validate the model are constrained by the number and type of products which have had demonstrable performance concerns over the past three years, with cost data available to the authors. The power of the validation is limited. The validation is considered a screening assessment.Practical implicationsThis work relates the characterization of risk with its potential cost and develops a scaling instrument to allow the incorporation of cost consequence into an FMEA.Originality/valueA ranking scale was developed that related severity and occurrence rank scores to a cost consequence rank that keys to a cost of quality figure (given as percent of sales) that would accompany a realization of the failure mode.