Failure Mode And Effect Analysis Method Research Articles

A novel FMEA model based on fuzzy multiple-criteria decision-making methods for risk assessment

PurposeRisk assessment is a very important step toward managing risks in various organizations and industries. One of the most extensively applied risk assessment techniques is failure mode and effects analysis (FMEA). In this paper, a novel fuzzy multiple-criteria decision-making (MCDM)-based FMEA model is proposed for assessing the risks of different failure modes more accurately.Design/methodology/approachIn this model, the weight of each failure mode is considered instead of risk priority number (RPN). Additionally, three criteria of time, cost and profit are added to the three previous risk factors of occurrence (O), severity (S) and detection (D). Furthermore, the weights of the mentioned criteria and the priority weights of the decision-makers calculated by modified fuzzy AHP and fuzzy weighted MULTIMOORA methods, respectively, are considered in the proposed model. A new ranking method of fuzzy numbers is also utilized in both proposed fuzzy MCDM methods.FindingsTo show the capability and usefulness of the suggested fuzzy MCDM-based FMEA model, Kerman Steel Industries Factory is considered as a case study. Moreover, a sensitivity analysis is conducted for validating the achieved results. Findings indicate that the proposed model is a beneficial and applicable tool for risk assessment.Originality/valueTo the best of authors’ knowledge, no research has considered the weights of failure modes, the weights of risk factors and the priority weights of decision-makers simultaneously in the FMEA method.

Application of the FMEA Method for the Risk Assessment in Raliway Transport According to the Requirements of PN-EN IEC 60812:2018-12 Standard

Abstract The paper presents the procedure of performing the safety assessment using the FMEA (Failure Mode and Effects Analysis) method, according to the latest version of the PN-EN IEC 60812:2018 standard. The attention was paid to the application of the method for the assemblies and subassemblies of rail vehicles, for which it is increasingly used. The example used in the following paper refers to the fire protection system of a rail vehicle that meets the requirements of the PN-EN IEC 60812:2018 standard. Performing the risk assessment at the design stage of railway products is a part of the customer’s requirements and is a key factor in the certification and placing them in service.

Multi-objective mathematical model based on fuzzy hybrid multi-criteria decision-making and FMEA approach for the risks of oil and gas projects

Purpose The purpose of this study is to provide a comprehensive framework for analyzing risk factors in oil and gas projects. Design/methodology/approach This paper consists of several sections. In the first section, 19 common potential risks in the projects of Pars Oil and Gas Company were finalized in six groups using the Lawshe validation method. These factors were identified through previous literature review and interviews with experts. Then, using the “best-worst multi-criteria decision-making” method, the study measured the weights associated with the performance evaluation indicators of each risk. Consequently, failure mode and effects analysis (FMEA) and the grey relational analysis (GRA)-VIKOR mixed method were used to rank and determine the critical risks. Finally, to assign response strategies to each critical risk, a zero-one multi-objective mathematical programming model was proposed and developed Epsilon-constraint method was used to solve it. Findings Given the typical constraints of projects which are time, cost and quality, of the projects that companies are often faced with, this study presents the identified risks of oil and gas projects to the managers of the oil and gas company in accordance with the priority given in the present research and the response to each risk is also suggested to be used by managers based on their organizational circumstances. Originality/value This study aims at qualitative management of cost risks of oil and gas projects (case study of Pars Oil and Gas Company) by combining FMEA, best worst and GRA-VIKOR methods under fuzzy environment and Epsilon constraints. According to studies carried out in previous studies, the simultaneous management of quantitative and qualitative cost of risk of oil and gas projects in Iran has not been carried out and the combination of these methods has also been innovated.

A critical analysis of the AIAG-VDA FMEA; does the newly released AIAG-VDA method offer improvements over the former AIAG method?

After several years of collaboration, The Automotive Industry Action Group (AIAG) and The German Association of the Automotive Industry (VDA) completed a harmonized version of their respective FMEA methods. Previous to the joint initiative, each organization had their own Failure Modes and Effects Analysis (FMEA) recommended methods & guidelines. The differing methods posed confusion among those automotive suppliers that supplied both markets. As a result, the AIAG & VDA FMEA 1st edition Handbook (2019) was created to mitigate the confusion, improve the overall FMEA development process, and to improve efficiency developing accurate, robust and effective FMEA's. The AIAG-VDA 1st edition (2019) may or may not have improved the method or offered efficiency gains to the FMEA development process. Early critique of the new method offered by Harpster (2018) stated "If the AIAG-VDA DFMEA methodology (which uses structure, function, and failure analyses to determine critical DFMEA content) is implemented, it will result in an automotive DFMEA process that is both considerably less effective and much more inefficient than the current methodology described in the AIAG 4th Edition FMEA manual". This result of this research is a critical, holistic review of the recently published (June 2019) AIAGVDA FMEA Handbook along with summarized advantages and disadvantages associated with the new automotive FMEA development process. While the new FMEA AIAG-VDA process offers several advantages, and results in a more robust FMEA, the increased complexity, need for dedicated software, and the learning curve associated with the new process may represent a significant barrier to improving the FMEA development process in the automotive community.

Manajemen Risiko Teknologi Informasi Pada Penerapan E-Recruitment Berbasis ISO 31000:2018 Dengan FMEA (Studi Kasus PT Pertamina)

Increasing the efficiency of time and human resources in the process of recruiting PT. Pertamina (Persero) to carry out its business processes that are spread throughout Indonesia is very much needed by implementing a website-based online recruitment system. Increased efficiency is obtained from a system that runs without constraints, while the weaknesses (vulnerabilities) in a system will cause great threats to the company, then the risk management of information technology on the application of the E-Recruitment system needs to be done by referring to ISO 31000: 2018 and risk assessment to get a Risk Priority Number (RPN), which is the priority of risk treatment for each risk attribute using the FMEA (Failure Modes and Effects Analysis) method based on ISO 31010: 2009 with the aim of knowing and assessing how much the threats and risks in an information system can become consideration of company stakeholders in implementing the system. Risks obtained in this study are 3 types of potential risks and 28 risk attributes, after a risk assessment has been obtained, the results are obtained that 7 risk attributes require special attention in the process of implementing the system so that it can run well in the future.

Determination of component categories using logic tree analysis

Sterilizer machine plays important role in crude palm oil. Component machine has an important function to determine a maintenance based on the failure. Component failure is used to determine a correct maintenance. The problem faced by the company today is the high downtime of the sterilizer making machine causes the sterilizer production process to be disrupted. Machine breakdown around 35,66 hours/month. Machine failure analysis using the Failure Mode and Effect Analysis (FMEA) method and the Logic Tree Analysis (LTA) method. The LTA method used to determine priority to each failure mode and to review functions and malfunctions produce categories A (evident), B (safety), C (Economic Problem) and D (Hidden Failure) with the largest percentage for category B. The FMEA method analyse the factors causing component failure and its effect on overall system function by giving a Risk Priority Number value (RPN) based on severity, occurrence, and detection. The FMEA method produces the highest RPN values for 5 components namely IGBT, Mosfet, Bearing Bushing, Rool Former, and V-Block. LTA method shows that B Category has the largest percentage of component category. The result of this research is to categorize component failure and determine the Risk Priority Number for sterilizer machine.

Decision-making for risk evaluation: integration of prospect theory with failure modes and effects analysis (FMEA)

PurposeThe aim of the present study is to overcome some of the limitations of the FMEA method by presenting a theoretical base for considering risk evaluation into its assessment methodology and proposing an approach for its implementation.Design/methodology/approachFuzzy AHP is used to calculate the weights of the likelihood of occurrence (O), severity (S) and difficulty of detection (D). Additionally, the prospect-theory-based TODIM method was integrated with fuzzy logic. Thus, fuzzy TODIM was employed to calculate the ranking of potential failure modes according to their risk priority numbers (RPNs). In order to verify the results of the study, in-depth interviews were conducted with the participation of industry experts.FindingsThe results are very much in line with prospect theory. Therefore, practitioners may apply the proposed method to FMEA. The most crucial failure mode for a firm's attention is furnace failure followed by generator failure, crane failure, tank failure, kettle failure, dryer failure and operator failure, respectively.Originality/valueThe originality of this paper consists in integrating prospect theory with the FMEA method in order to overcome the limitations naturally inherent in the calculation of the FMEA's RPNs.

A New Integrated Approach for Risk Evaluation and Classification With Dynamic Expert Weights

Failure mode and effect analysis (FMEA), as a proactive reliability management technique, has been widely employed to reduce the risk of systems and assure the quality of products in various industries. Nevertheless, the traditional FMEA method shows many weaknesses when used in real-life scenarios. This causes the dilemma for practitioners that it is not great as expected. Many alternative risk priority models have been developed to enhance the capacity of FMEA, but the majority of them focus on how to acquire a complete ranking of failure modes. In this article, we propose a novel FMEA approach using hesitant uncertain linguistic Z numbers (HULZNs) and density-based spatial clustering of applications with noise (DBSCAN) algorithm to assess and cluster the risk of failure modes. The HULZNs are adopted to represent the uncertain and hesitant risk evaluation information of FMEA team members. The normal DBSCAN algorithm is improved to cluster the recognized failure modes into different risk classes. Moreover, the weights of FMEA experts are dynamically obtained with a weight adjustment method. Finally, a practical case of a geothermal power plant is given to demonstrate the effectiveness and validity of our introduced FMEA approach.

Development and Research FMEA Expert Team Model

This paper presents a description and research of the model of the team of experts in the application of the Failure Mode and Effects Analysis (FMEA). The main factors affecting the efficiency of the team of experts are highlighted. The generalized mathematical model of influence of these factors on efficiency of work of team is described. The research of this model on three different sets of initial data characterizing typical situations arising at the enterprise at application of the FMEA method is presented. An assessment was made of the simultaneous change of two types of competencies and motivation of both the participants and the team-wide single parameter. The model is studied on three typical situations with a different set of initial conditions and the corresponding parameters. The use of this technique allows for a preliminary assessment of the change in the effectiveness of the analysis by a team of specialists over time, which allows on the one hand to plan correctly not only the application of the FMEA itself within the overall schedule of work, but also to properly organize the training of the team. In addition, this technique will allow you to visually compare the various teams with each other and choose the most optimal or effective team.

Development of a system for risk analysis in treatment with unsealed radioactive substances in nuclear medicine

With respect to the amendment of the Radiation Protection law it is required to estimate the risks of treatments with ionizing radiation regarding patient safety. This task is in the responsibility of a medical physics expert. The risks were estimated using the Failure Mode and Effects Analysis (FMEA) as suggested by the Federal Office for Radiation Protection (BfS) and the scientific societies. For Radioiodine Therapy, Radiosynoviorthesis, Peptide Receptor Radionuclide Therapy, and Selective Internal Radiation Therapy, respectively, the involved processes were analyzed, structured and scored. This was done both individually by all people involved in the process and by all participants together. For processes with risk priority numbers > 125 countermeasures were introduced. The risk priority number (RPZ) was calculated as the product of severity of the event, the probability of the occurrence of the event and the detection probability. The greatest risks were mistaken identity, incorrect estimations of activity and organ masses and a lack of compliance of the patients. The individual risk estimation revealed a high variability between the different professions, that was reduced significantly by discussion led by an external moderator. For the highest RPZ countermeasures were formulated which impact needs to be reviewed in the future. Nuclear medical therapies were assessed as very safe, the revealed risks are very low in respect to patient safety. FMEA method was a useful tool to identify processes with potential for optimization. The chosen procedure can be easily adopted in other nuclear medicine facilities considering structure specific aspects like technical and personal equipment and procedures. Then further risks might be detected or the here identified risk might be assessed differently.

Planning for Improvement of Carton Box Production Process using Lean Manufacturing Approach to Increase Production Results at PT. Kati Kartika Murni

Abstract—PT. Kati Kartika Murni is a company engaged in the packaging industry. This company applies a make to order (MTO) system. Carton Boxes are the focus of research because it have the highest number of requests by 55%. Problems faced by PT. Kati Kartika Murni namely the number of customer requests not yet met. This research was conducted to increase the production of carton boxes to 3600 boxes. Increasing the amount of production is done by lean manufacturing approach, namely by identifying waste and eliminating existing waste. Manufacturing lead time before repair is 17811.7 seconds, process cycle efficiency before repair is 44.4489%, and takt time is 4.645 seconds. The number of production before the design of repairs is 3379 boxes, where orders have not been fulfilled with the available time. The highest waste based on the waste assessment model and value stream analysis tools are defect and transportation. The analysis was conducted using the Failure Mode and Effect Analysis (FMEA) method to determine the type of waste that needs to be eliminated. The highest RPN of 448 is the faded color defect in the flexo process and the second highest RPN of 392 is the overlap defect in the corrugating process. Waste transportation analysis using FMEA method shows the highest RPN value of 448, namely at the time of operation and material movement on the production floor. The design of improvements to eliminate waste transportation is to add a roller conveyor functioning as material handling between work stations. One piece flow addition for the corrugating process to flexo. After an improvement plan is made, the Manufacturing lead time is 15634.2 seconds and the Process cycle efficiency is 50.64%. The amount of production after the design improvement is 3850 boxes, where orders have been fulfilled with the available time.

Integrated Decision-Making Approach Based on SWARA and GRA Methods for the Prioritization of Failures in Solar Panel Systems under Z-Information

Encountering a problem or error in the final stages of providing products or services increases costs and delays scheduling. The key task is to ensure quality and reliability in the early stages of the production process and prevent errors from occurring from the beginning. Failure mode and effect analysis (FMEA) is one of the tools for identifying potential problems and their impact on products and services. The conventional FMEA technique has been criticized extensively due to its disadvantages. In this study, the concepts of uncertainty and reliability are considered simultaneously. The processes of weighting risk factors, prioritizing failures by using the stepwise weight assessment ratio analysis (SWARA)–gray relational analysis (GRA) integrated method based on Ζ-number theory and complete prioritization of failures are implemented. Crucial management indices, such as cost and time, are considered in addition to severity, occurrence and detection factors along with assigning symmetric form of the weights to them. This, in turn, increases the interpretability of results and reduces the decision-maker’s subjectivity in risk prioritization. The developed model is implemented on solar panel data with 19 failure modes determined by the FMEA team. Results show that the proposed approach provides a more complete and realistic prioritization of failures than conventional FMEA and fuzzy GRA methods do.

Failure mode and effects analysis (FMEA) for risk assessment based on interval type-2 fuzzy evidential reasoning method

Failure mode and effect analysis (FMEA) has been widely adopted to define, identity, and remove potential and recognized hazards. As an indicator in traditional FMEA, the risk priority number (RPN) is an effective tool for measuring risk and the calculation of RPN is also very simple. Nevertheless, there are many drawbacks in the conventional FMEA method. It is necessary to seek approaches that can make up for the deficiency of traditional FMEA method and strengthen assessment capability of ranking failure modes according to three relevant risk factors. This paper presents a way to combine interval type-2 fuzzy sets (IT2FSs) with evidential reasoning (ER) method, which is able to overcome some disadvantages of the conventional FMEA approach and deal with uncertainties more efficiently. First, we give a more precise expression of the risk factors in the form of IT2FSs and gain the relative weight of three risk factors. Second, one can judge the failure modes in relation to each risk factors with belief structures. Finally, the ER method is used to combine the belief structures under the weight of the three risk factors. To verify the feasibility of the method, an application for steam valve system is performed and the obtained results show the effectiveness of the method.

Failure modes and effects analysis for testicular sperm extraction management process.

Failure modes and effects analysis (FMEA) is a proactive risk evaluation to identify and reduce potential failures that may occur during a procedure within a quality management programme. One of the procedures performed in assisted reproduction technology centres is testicular sperm extraction (TESE) as treatment of azoospermic patients. To examine the risks associated with the 'TESE management' process, we applied the FMEA method, before and after implementation of corrective measures defined in a standard operative procedure (SOP). A multidisciplinary team was formed. Possible causes of failures and their potential effects were identified, and risk priority number (RPN) for each failure was calculated. The FMEA team identified 4 process activities, 19 process steps and 19 potential failure modes. The re-evaluation after the corrective measures disclosed a reduction in the number of phases with high/moderate risk (pre-SOP: n=13; post-SOP: n=3). Improvements in the traceability system removed 11 out of 13 (85%) steps with a low risk of occurrence. In our experience, FMEA is efficient in helping multidisciplinary groups to strengthen knowledge and awareness on routine processes, identifying critical steps and planning practical improvements for a better compliance with criteria of traceability and conformity of biological samples and patients.

A Quantitative Failure Analysis on Capacity Fade in Rechargeable Lithium Metal Cells

Rechargeable lithium battery (RLB) technology is transforming portable devices, vehicle electrification, and grid modernization. To make RLB durable, reliable and safe, conducting failure mode and effect analysis (FMEA) to identify failure mechanism under the operating conditions is very desirable. However, this ability is often overlooked or even lacking. The failure analysis (FA) is often conducted by laboratory testing and postmortem analysis, and the knowledge typically empirical. Here we present a quantitative approach for FMEA that can reveal how failure modes and effects reduce the capacity of a RLB. This approach is based on the state of the battery for FMEA, contrary to the conventional approach based on operating or testing conditions. The key aspect of this FMEA method is to convert the experimental results to a state-of-charge (SOC)-based analytic methodology. Such a conversion can separate the thermodynamic and kinetic attributes of capacity fade based on compositional correspondence in the electrode, so the loss and the decreased utilization of the active materials can be determined respectively.

Analysis of the quality of wheel chain products at UPT logam Yogyakarta using FMEA method

Product quality measurement is an important aspect of the production process. This study aims to determine the types of defects that often occur and find a recommendation for improvement to CNC machine product of Takamaz GSL 15 at Technical Implementing Unit Metal Yogyakarta. In this study, a Pareto diagram is used for analysis the types of defects. Analysis of priority value regarding severity (S), occurrence (O), and detection (D) characteristics is performed by using Failure Mode and Effect Analysis (FMEA) method. Meanwhile, Fishbone is used to analyze more deeply about the potential caused by the type of defect. This study succeeded in finding four types of records on the product; they are cracked pinhole, imperfect castings, hole defects on the surface, and minus drain lines. This study recommend to include periodic and ongoing supervision of the metal casting process, make metal wheel chain in one production line, use modern equipment or machines, replace the drill bits periodically during machining process and replace sandpaper with a softness level according to SOP.

Application of the dynamic FMEA in the reliability analysis of DCS

Digital distributed instrumentation and control system (DCS) is critical to the safety of nuclear power plants (NPPs). Static analysis methods developed from analog control system are not applicable to DCS due to its enhanced dynamic interactions and complex structure of hardware/software/firmware. The enhanced dynamic interactions of DCS include both sequence and timing factors, which are hardly modelled in the traditional Failure Mode and Effect Analysis (FMEA). In this study, dynamic FMEA (DFMEA) method based on simulation technology is put forward for the design and review of DCS in NPP. DFMEA based on real DCS hardware and software is developed to reveal the dynamic failure paths and failure modes. The results of DFMEA can well support the establishment of the dynamic fault tree/event tree in the review of NPP DCS, which reduces the dependency on the analyst’s experience significantly.

Interval-valued neutrosophic failure mode and effect analysis

Failure mode and effects analysis (FMEA) is a structured approach for discovering possible failures that may occur in the design of a product or process. Since classical FMEA is not sufficient to represent the vagueness and impreciseness in human decisions and evaluations, many extensions of ordinary fuzzy sets such as hesitant fuzzy sets, intuitionistic fuzzy sets, Pythagorean fuzzy sets, spherical fuzzy sets, and picture fuzzy sets. Classical FMEA has been handled to capture the uncertainty through these extensions. Neutrosophic sets is a different extension from the others handling the uncertainty parameters independently. A novel interval-valued neutrosophic FMEA method is developed in this study. The proposed method is presented in several steps with its application to an automotive company in order to prioritize the potential causes of failures during the design process by considering multi-experts’ evaluations.

Constructing network enterprise structure to create innovative products

The subject of the study is the formation of the structure of a network enterprise, considered as a set of interacting enterprises in a networked Internet environment that implements a value chain. To build the structure of the network enterprise, it is proposed to use and support the ontology of the network enterprise, which conceptually reflects the models of products and related production and business processes throughout the life cycle. At the same time, the focus is on the implementation of flexible processes for creating innovative products using intelligent model-oriented technologies.The purpose of the study is to build an algorithm for forming the structure of a network enterprise that would ensure the best implementation of the value chain with minimal risks of mismatch of designs and production processes with qualitative value characteristics and requirements for an innovative product. The construction of an algorithm for forming the structure of a network enterprise involves solving the problems of modeling the structure of an innovative product based on an analysis of qualitative value characteristics and requirements for product components, its creation processes, distribution of roles of enterprise participants and analysis of their capabilities.Methods.As the main research method is the method of constructing a model of “digital thread” of creating an innovative product. The most complete application of this method is carried out as part of the reference model of enterprise architecture for Industrie 4.0 (RAMI). The resulting conceptual model of an innovative product and related production and business processes is implemented using an ontological approach. It is proposed to use a combination of QFD (Quality Function Deployment) methods for deploying the structure of a network enterprise and analyzing the types and consequences of potential FMEA (Failure Mode and Effects Analysis) inconsistencies.The main results of the studyare ontology and the algorithm for forming the structure of the network enterprise. A distinctive feature of the proposed ontology of the network enterprise is a clear separation of the valuable qualitative characteristics of the product and the requirements for its creation, as well as the allocation of the abilities of participants in enterprises to implement the necessary processes. The novelty of the presented algorithm for the formation of the structure of a network enterprise lies in the combined application of the QFD and FMEA methods, as well as in the iteration of modeling the structure of an innovative product from the position of the best implementation of quality value characteristics and functional requirements.Conclusions, prospects.The proposed algorithm for creating the structure of a network enterprise allows you to get the best decisions on the criterion for assessing the highest rating for the implementation of quality characteristics and requirements for the components of the value chain and its participants, provided that minimal risk assessments of the mismatch between the designs and processes of creating innovative products are obtained. The developed ontology and the algorithm for forming the structure of the network enterprise is of practical importance for creating an intelligent system for supporting the adoption of innovative decisions for the dynamic construction of network enterprises in the Internet environment.

The risk analysis at working with a chainsaw

Forestry in Slovakia has recently got very fast tendency of research in all levels. The introduction of complex machines and equipment, the application of new advanced technologies, the tendency to decrease energy consumption, material difficulty of products, requirements on high reliability of machines and automation in operation impose the necessity for the search of theoretical basics for wood production processes and utilization of new developing forest and wood processing techniques. The work with a chain saw is risky and has negative impact on the health of workers. It has been clear from recent findings. The limitation of these impacts has influence on technical, technological and organizational actions serving as preventive ones. That is the reason why the famous chain saw producers established different technical supports which have the influence on decrease of vibrations and noise. It is necessary to realize several actions within the maintenance of chain saws to fulfil the goals of a technical action. The paper deals with risk analysis by usage Failure Modes and Effects Analysis (FMEA), which was implemented on STIHL motor chainsaw. We identified the potential failures, then we allocated to the value of occurrence, significance and detectability in the process and we also calculated the risk priority number (RPN). Application of the FMEA method allows flexibility in the case of unexpected situations and optimization of human potential abilities. FMEA is a tool preventing outages operational reliability and preventive tool for ensuring the maintenance of facilities. There are several methods of information processing regarding to reliability parameters, but some of them are very difficult and in standard operational conditions are not usable. The method of information analysis mentioned below is simple but precise enough for implementation in real working conditions.