Purpose The classification of aircraft failures has been a significant part of functional hazard analysis (FHA). Aiming at the shortcomings of the traditional FHA method in the evaluation of aircraft risk, the purpose of this paper is to put forward a new approach by combining the gray comprehensive relation calculation method in the gray system theory with the traditional FHA in order to deal with the problem of “little data, poor information.” Design/methodology/approach This paper combines FHA, 1–9-scale method and gray relation analysis. At first, aircraft failure scenarios are chosen and data from experts are collected; then gray system theory is applied to find the relevance of such scenarios. Finally, the classification according to relevance is determined. Findings In the past, “little data, poor information” made it difficult for researchers to implement FHA. In this paper, the authors manage to deal with the problem of “poor information” and provide an approach to find the seriousness of aircraft failure. Research limitations/implications Due to the use of expert-evaluating methods, the classification of failures is still a little subjective and can be improved in this area. In the future, the method can be improved from the perspective of combining FMEA to analyze more complex indicators or using multisource heterogeneous solutions to solve fuzzy numbers, probabilities, gray numbers and indicators that cannot be assigned. Practical implications The paper uses FHA to divide the failure state and establishes a gray evaluation model of the aircraft failure state classification to verify the relevant method. Some aircraft safety design requirements are used to check the safety hazards of the aircraft during the design process, and to provide rational recommendations for the functional design of the aircraft. Social implications Improving the safety of aircraft is undoubtedly of great practical significance and has become a top priority in the development of the civil aviation industry. In this paper, the FHA method and the failure state of the aircraft are studied. The original FHA method is innovated by using the gray system theory applicable to the poor information state. Therefore, to some extent, this study has significance for improving the safety of civil aircraft flight, ensuring people’s travel safety and enhancing the society’s trust in civil aviation. Originality/value The main innovation of this paper is integrating the FHA method and the gray system theory. This study calculates the comprehensive relation degree of each failure under different flight stages, and uses FHA to divide the failure state, and finally establishes a gray evaluation model of the aircraft failure state classification to analyze the different conditions of the landing gear brake system, so that it improves the present situation, and the problem with the character of “little data, poor information” can be addressed better.
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