Improved FMEA based on IVF and fuzzy VIKOR method: A case study of workpiece box system of CNC gear milling machine

Failure mode and effect analysis (FMEA) is a tool used to define, identify, and prevent known or unknown potential risks. An improved FMEA based on interval triangular fuzzy numbers (IVF) and fuzzy VlseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR) method is proposed in this study to solve problems of expression and processing of uncertain information, weights of risk factors, and ranking of failure modes in traditional FMEA. Linguistic variables are used to evaluate failure modes level and relative importance of risk factors and are expressed via interval-valued triangular fuzzy number. Determining the subjective weights of risk factors using fuzzy AHP, calculating the objective weights of risk factors using the extended VIKOR method, and obtaining the comprehensive weights of risk factors via ICWGT are proposed for solving the weight problem of risk factors. Finally, the fuzzy VIKOR method is used to rank risk priority of failure modes. The proposed method is used to evaluate workpiece box system of CNC gear milling machine and the results are compared with the findings of other methods to verify effectiveness and rationality of the proposed method.     

Fuzzy-based risk priority number in FMEA for semiconductor wafer processes

Semiconductor wafer manufacturing processes are considered to be complex and require considerable manpower and financial investment. Effective control to promote wafer yield is thus a very important issue. Many computational problems in traditional failure mode approaches, such as variable selection and data collection, are far too dependent on the experience of engineers, with a lack of specifically quantified values. Therefore, there are significant differences between the results of research and the actual processes. Although several researchers have revised the failure mode computation, the occurrence results continue to differ from the actual quantified values. The potential failure mode in semiconductor wafer manufacturing processes is effectively discussed using linguistic fuzzy variables to replace the severity and detection in the failure mode for re-calculation and sorting, along with the occurrence acquired from the wafer processes yield change. Based on the results of engineering experiments, the use of a risk priority number can effectively overcome the problem of a lack of objectivity in the traditional failure mode and effect analysis, as well as accurately distinguish the priority of the key failure factors so that the research results become more complete.     

An interval probability-based FMEA model for risk assessment: A real-world case

Failure mode and effect analysis (FMEA) is an effective quality tool to eliminate the risks and enhance the stability and safety in the fields of manufacturing and service industry. Nevertheless, the conventional FMEA has been criticized for its drawbacks in the evaluation process of risk factors or the determination of risk priority number (RPN), which may lead to inaccurate evaluation results. Therefore, in this paper, we develop a novel FMEA method based on rough set and interval probability theories. The rough set theory is adopted to manipulate the subjectivity and uncertainty of experts' assessment and convert the evaluation values of risk factors into interval numbers. Meanwhile, the interval exponential RPN (ERPN) is used to replace the traditional RPN due to its superior properties, eg, solving the problems of duplicate numbers and discontinuity of RPN values. Furthermore, an interval probability comparison method is proposed to rank the risk priority of each failure mode for avoiding the information loss in the calculation process of RPN. Finally, a real case study is presented, and the comparison analysis among different FMEA methods is conducted to demonstrate the reliability and effectiveness of the proposed FMEA method.     

FMEA在商品包装设计中的应用

介绍了FMEA的思想和应用特点,以啤酒包装为例分析了商品流通过程中包装所起的作用和可能出现的失效模式,并讨论了其影响;通过风险矩阵等方法对这些潜在的风险进行了分析,针对可能造成的影响给出了相应的措施,分析了其效果。以商品在流通中的物流过程为对象,提供了包装设计的具体步骤,对包装的绿色设计和最优应用提供了一条新颖的思路。     

An improved FMEA method based on the linguistic weighted geometric operator and fuzzy priority

Using the group linguistic information aggregation method, this research improved upon conventional failure mode and effect analysis (FMEA), which had the problems of the inevitable subjectivity of expert evaluations, and of the difficulty of determining the weights of experts' evaluations. First, this research treated the three risk factors of FMEA evaluation as linguistic variables and introduced a linguistic weighted geometric (LWG) operator to implement algebraic operations on the results of expert evaluations. This treatment overcame the disadvantage of fuzzy theory-based methods in which decision-making information could be lost due to the twice conversion process. Second, the weights of experts' evaluations were calculated based on the consistency of experts' ranking using a fuzzy priority method. This method placed a lower weight for the experts whose evaluation departed from group consensus, and therefore decreased the impact of the unfairness of experts on evaluation results. Finally, this article demonstrated the effectiveness and applicability of this method by an example of failure-mode analysis on the grinding wheel system of a numerical control machine.     

FMEA在过程管理中的应用

2000版的ISO9000标准明确提出过程管理的方法。分析了质量管理体系的现状和实施过程管理的必要性。把失效模式及后果分析（FMEA）作为过程管理的一种工具提出来，并通过一个实例具体介绍了在过程管理中使用FMEA的步骤。     

结合解释结构模型与网络分析法于FMEA的应用

引入解释结构模型法,分析出控制措施之间的层次、顺序关系,再用网络分析法考虑控制措施间的相依关系,进行客观权重的计算,作为FMEA中的新探测度,再进行新RPN的计算。以回炉焊接制程提升为研究案例,比较新方法与传统方法的差异,发现优先改善项目与改善顺序的不同产生不同结果,提升了改善的效果。     

Applying UGF Concept to Enhance the Assessment Capability of FMEA

The purpose of this paper is to propose a modified version of Failure Mode and Effects Analysis (FMEA) to alleviate its drawbacks. FMEA is an important tool in risk evaluation and finding the priority of potential failure modes for corrective actions. In the proposed method, the Universal Generating Function (UGF) approach has been used to improve the assessment capability of the conventional Risk Priority Number (RPN) in ranking. The new method is named as URPN. It generates the most number of unique values in comparison with the previous methods and considers relative importance for the parameters while it is easy to compute. More unique numbers help to avoid from having the same priority level for different failure modes which represent various risk levels. A case study has been employed to demonstrate that the URPN not only can improve the shortcomings but also is able to provide accurate values for risk assessment. Copyright © 2015 John Wiley & Sons, Ltd.     

FMEA下的超市食品HACCP计划制定与实现

结合故障模式与影响分析(FMEA)以及危害分析和关键控制点(HACCP)方法,可以分析超市食品供应中的潜在故障模式和决定给予风险优先级的关键控制点,从而可以产生一个HACCP计划.这一方法在一个超市产生猪肉的供应计划中成功地得到应用.     

一种综合赋权的改进FMEA风险评估方法

针对传统故障模式和影响分析(failure mode and effects analysis, FMEA)方法中的未考虑风险因子权重以及风险因子权重难确定这一问题,提出一种综合赋权的改进FMEA风险评估方法。该方法首先通过FMEA团队明确评估对象和FMEA范围,然后列出所有潜在故障模式,对故障模式进行打分,得到所有的专家打分评估表,再通过语言变量转化为直觉模糊数。由层次分析法确定主观权重,由数据本身确定客观权重,使用直觉模糊混合加权算子(intuitionistic fuzzy hybrid weighted, IFHW)算子集结评价信息,得到所有的故障模式的得分函数,最后基于风险最大化选取每个故障模式的最大分数,进行排名,得到最终的故障模式风险顺序。通过对静电纺丝设备进行FMEA分析,并与其他方法进行比较,验证了所提方法的可行性。     

基于灰色关联分析的故障模式危害性决策方法

 通过考虑产品设计者的设计意图及偏好,计算了各危害性故障模式对危害性理想故障模式的灰关联度,依此对各故障模式危害性进行了排序,克服了传统风险优先数法当RPN值相等或相近时各故障模式危害程度难以比较以及各个风险优先数因子无相对权重的问题.最后以某产品的工艺FMECA分析为例,进行了验证.     

Risk analysis of human error in interaction design by using a hybrid approach based on FMEA,SHERPA, and fuzzy TOPSIS

User experience is the focus of interaction design, and designing for errors is crucial for improving user experience. One method of designing for errors is to identify human errors and then initiate corrective actions on high-risk errors to reduce their adverse effects. In this study, we proposed a hybrid approach for risk analysis of human error concerning user experience of interactive systems. In this approach, systematic human error reduction and prediction approach (SHERPA) is first adopted to identify human error concerning user experience. Subsequently, failure mode and effect analysis (FMEA) is used to analyze the risk factors of the error, including occurrence, severity, and detection. Fuzzy technique for order preference by similarity to ideal solution (TOPSIS) is then used to calculate the risk priority number to rank the errors. Finally, corrective actions for high-risk errors are recommended. An in-vehicle information system was used to demonstrate the proposed approach. The results indicated that the proposed approach can effectively analyze the risk of human error concerning user experience and be used as a universal reliability approach for improving user experience in interaction design.     

Failure mode and effects analysis by integrating Bayesian fuzzy assessment number and extended gray relational analysis‐technique for order preference by similarity to ideal solution method

Failure mode and effects analysis (FMEA) is a prospective risk assessment tool used to identify, assess, and eliminate potential failure modes (FMs) in various industries to improve security and reliability. However, the traditional FMEA method has been criticized for several shortcomings and even the improved FMEA methods based on predefined linguistic terms cannot meet the needs of FMEA team members' diversified opinion expressions. To solve these problems, a novel FMEA method is proposed by integrating Bayesian fuzzy assessment number (BFAN) and extended gray relational analysis‐technique for order preference by similarity to ideal solution (GRA‐TOPSIS) method. First, the BFANs are used to flexibly describe the risk evaluation results of the identified failure modes. Second, the Hausdorff distance between BFANs is calculated by using the probability density function (PDF). Finally, on the basis of the distance, the extended GRA‐TOPSIS method is applied to prioritize failure modes. A simulation study is presented to verify the effectiveness of the proposed approach in dealing with vague concepts and show its advantages over existing FMEA methods. Furthermore, a real case concerning the risk evaluation of aero‐engine turbine and compressor blades is provided to illustrate the practical application of the proposed method and particularly show the potential of using the BFANs in capturing FMEA team members' diverse opinions.     

Integrating failure analysis and risk analysis with quality assurance in the design phase of medical product development

Today, manufacturing operates as a global network, which has created more awareness of the quality of products and services. A systematic and rational way of managing quality assurance is currently lacking. This can cause serious problems in sectors such as the medical industry, as product failure may not only cause time delays, but also create risks for the health and safety of patients and users. This paper proposes a quality assurance approach that incorporates risk analysis (based on ISO14971) and failure analysis (based on FMEA) into the product design phase to assure product quality in the short term and facilitate global manufacturing practices in the long run. The proposed approach includes a Markov model to predict product failure from a customer perspective, which serves as a checkpoint for feedback to provide a basis for quality assurance. A medical equipment firm is used as a test-bed to illustrate how the proposed approach works and to verify its effectiveness.     

基于FMEA和FTA的老年人汽车人机界面交互设计研究

目的 提升老年人汽车界面满意度,设计适合老年人使用的汽车界面.方法 提出基于失效模式与效应分析(FMEA)、故障树分析(FTA)的研究方法,首先成立会议小组进行SHERPA分析,绘制汽车界面层次任务分析图;随后运用FMEA找出汽车界面中的潜在失效模式,计算风险优先数值;接着选取风险优先数值高的失效模式,运用FTA寻找其发生的原因,对其以图形化表示;再对故障树进行定性定量分析,计算故障树的最小切集和失效事件发生概率,找到失效发生的核心因素;最后对失效事件进行改良并对改良后的结果进行验证.结论 以老年人汽车界面为例进行研究,该方法可以有效发现老年人操作汽车界面发生错误的原因,不仅可以帮助设计师找到改良的重点,还可以使老年人获得良好的驾驶体验.     

Integrated analysis of the performance of TQM tools and techniques: a case study in the Taiwanese motor industry

Most studies of total quality management (TQM) have focused on the managerial aspects and associated success factors of TQM programmes, whereas relatively few studies have examined the appropriateness and performance of the large number of available tools and techniques that actually implement TQM practices. To assist in determining the best strategy for improving the performance of TQM tools and techniques, the present study integrates a modified importance–performance matrix with elements of failure mode and effects analysis (FMEA) to provide a comprehensive methodology for assessing and improving the performance of TQM tools and techniques in the Taiwanese motor industry. The methodology presented here can be applied in a variety of industries, including the Taiwanese motor industry, to enable efficient utilisation of TQM tools and techniques and thus improve quality, reduce costs and shorten cycle times.     

Consensus building in linguistic failure mode and effect analysis: A perspective based on prospect theory

As one of many scientific and efficient risk assessment approaches, failure mode and effect analysis (FMEA) has been widely applied across various fields. There are two core issues in the FMEA approach: identifying the latent failure modes of the systems, products, processes and services and the risk assessment and the prioritization of those failure modes. Then, corrective measures must be taken in a timely and accessible manner to prevent the occurrence of failure modes with higher risk levels. In practice, several FMEA members from different fields are usually involved in the FMEA implementation process; the risk assessment information given by them may vary greatly. Therefore, it is necessary to integrate a consensus-building process into FMEA. Meanwhile, the psychological behaviours of FMEA members have had a great impact on the final prioritization of failure modes. Prospect theory is an effective approach for describing individual psychological behaviours. Therefore, this paper presents a novel linguistic FMEA approach to address the consensus issue from the perspective of prospect theory. In the proposed linguistic FMEA approach, a consensus measurement approach based on prospect theory is constructed. Then, a novel feedback adjustment mechanism is designed in which FMEA members can adjust not only their assessment information but also their reference points to achieve an acceptable consensus degree. Eventually, a practical application is used to show the validity and applicability of the proposed linguistic FMEA approach.     

Test sample allocation method for testability verification test

An extended failure mode effect and criticality analysis (FMECA)-based sample allocation method for testability verification is presented in this study to deal with the poor representativeness of test sample sets and the randomness of the testability evaluation results caused by unreasonable selection of failure samples. First, the fault propagation intensity is introduced as part of the extended information of FMECA, and the sample allocation impact factors of component units and failure modes are determined under this framework. Then, the failure mode similarity and impact factor support are defined, and the game decision method for weighing the relationship between similarity and support is proposed to obtain the weight of failure mode impact factor. Finally, a two-step allocation framework of test samples is formulated to realize the sample allocation of component units and failure modes. This method is applied to the testability verification test of a launch control system. Results show that this method can obtain more representative test samples compared with the traditional sample allocation method while effectively reducing randomness of single testability evaluation result.     

An improved failure mode and effects analysis method based on uncertainty measure in the evidence theory

mode and effects analysis (FMEA) is an effective tool to assess the risk of a system or process under uncertain environment. However, how to handle the uncertainty in the subjective assessment is an open issue. In this paper, a novel method to deal with the uncertainty coming from subjective assessments of FMEA experts is proposed in the framework of Dempster–Shafer evidence theory. First, the uncertain degree of the assessment is measured by the ambiguity measure. Then, the uncertainty is transformed to the reliability of each FMEA expert and the relative importance of each risk factor. After that, the assessments from FMEA team will be fused with a discounting-based combination rule to address the potential conflict. Moreover, to avoid the situation that different risk priorities of failure modes may have the same ranking based on classical risk priority number method, the gray relational projection method (GRPM) is adopted for ranking risk priorities of failure modes. Finally, an application of the improved FMEA model in sheet steel production process verifies the reliability and validity of the proposed method.     

Group-based product scheme-screening decision method based on fuzzy AHP and evidential reasoning theory

Selecting the favourable product scheme is the first step to successful new product development (NPD). There are usually large numbers of uncertainties in product scheme evaluation and screening process of NPD due to lack of or incomplete reliable information. Considering fully the uncertainties and then conducting correct reasoning could guarantee reliability and rationality of scheme-screening results. As an extension of analytic hierarchy process (AHP), fuzzy AHP inherits multi-merits of the AHP approach and is capable of dealing with fuzzy information effectively, but it still has two weaknesses. One is the well-known ranking reversal problem. Although several researchers have analysed the reasons, we think the root cause for ranking reversal problem is due to the fact that AHP treats weights of attribute criteria and performance scores of alternatives in the same way. Therefore, we intend to deal with attribute weights and performance scores of alternatives separately and introduce evidential reasoning (ER) theory, which is good at uncertain reasoning, into fuzzy AHP to calculate the performance scores of alternatives. On the other hand, in view of the difficulty in resolution for fuzzy weights from fuzzy comparison matrix, a linear goal-programming model is proposed to calculate fuzzy weights, whose objective is to minimise the inconsistency degree of comparison matrix. By combining fuzzy AHP with ER, a group-based hybrid decision model FAHP-ER is developed. The hybrid model not only gets a great improvement in the capability of dealing with uncertainty, but also reflects the most real decision scenario and thinking process of the decision maker. Finally, a case study for schemes screening of the rotor and bearing system in the turbine generator is presented to demonstrate the application of the hybrid decision method.