A novel approach for failure mode and effects analysis using combination weighting and fuzzy VIKOR method

Failure mode and effects analysis (FMEA) is one of the most popular reliability analysis tools for identifying, assessing and eliminating potential failure modes in a wide range of industries. In general, failure modes in FMEA are evaluated and ranked through the risk priority number (RPN), which is obtained by the multiplication of crisp values of the risk factors, such as the occurrence (O), severity (S), and detection (D) of each failure mode. However, the conventional RPN method has been considerably criticized for various reasons. To deal with the uncertainty and vagueness from humans’ subjective perception and experience in risk evaluation process, this paper presents a novel approach for FMEA based on combination weighting and fuzzy VIKOR method. Integration of fuzzy analytic hierarchy process (AHP) and entropy method is applied for risk factor weighting in this proposed approach. The risk priorities of the identified failure modes are obtained through next steps based on fuzzy VIKOR method. To demonstrate its potential applications, the new fuzzy FMEA is used for analyzing the risk of general anesthesia process. Finally, a sensitivity analysis is carried out to verify the robustness of the risk ranking and a comparison analysis is conducted to show the advantages of the proposed FMEA approach.     

Failure mode and effects analysis based on a novel fuzzy evidential method

Failure mode and effect analysis (FMEA) has been widely applied to examine potential failures in systems, designs, and products. The risk priority number (RPN) is the key criteria to determine the risk priorities of the failure modes. Traditionally, the determination of RPN is based on the risk factors like occurrence (O), severity (S) and detection (D), which require to be precisely evaluated. However, this method has many irrationalities and needs to be improved for more applications. To overcome the shortcomings of the traditional FMEA and better model and process uncertainties, we propose a FMEA model based on a novel fuzzy evidential method. The risks of the risk factors are evaluated by fuzzy membership degree. As a result, a comprehensive way to rank the risk of failure modes is proposed by fusing the feature information of O, S and D with Dempster–Shafer (D–S) evidence theory. The advantages of the proposed method are that it can not only cover the diversity and uncertainty of the risk assessment, but also improve the reliability of the RPN by data fusion. To validate the proposed method, a case study of a micro-electro-mechanical system (MEMS) is performed. The experimental results show that this method is reasonable and effective for real applications.     

Risk evaluation in failure mode and effects analysis with extended VIKOR method under fuzzy environment

Failure mode and effects analysis (FMEA) is a widely used risk assessment tool for defining, identifying, and eliminating potential failures or problems in products, process, designs, and services. In traditional FMEA, the risk priorities of failure modes are determined by using risk priority numbers (RPNs), which can be obtained by multiplying the scores of risk factors like occurrence (O), severity (S), and detection (D). However, the crisp RPN method has been criticized to have several deficiencies. In this paper, linguistic variables, expressed in trapezoidal or triangular fuzzy numbers, are used to assess the ratings and weights for the risk factors O, S, and D. For selecting the most serious failure modes, the extended VIKOR method is used to determine risk priorities of the failure modes that have been identified. As a result, a fuzzy FMEA based on fuzzy set theory and VIKOR method is proposed for prioritization of failure modes, specifically intended to address some limitations of the traditional FMEA. A case study, which assesses the risk of general anesthesia process, is presented to demonstrate the application of the proposed model under fuzzy environment.     

Fuzzy failure modes and effects analysis by using fuzzy TOPSIS-based fuzzy AHP

Failure mode and effects analysis (FMEA) is a widely used engineering technique for designing, identifying and eliminating known and/or potential failures, problems, errors and so on from system, design, process, and/or service before they reach the customer (Stamatis, 1995). In a typical FMEA, for each failure modes, three risk factors; severity (S), occurrence (O), and detectability (D) are evaluated and a risk priority number (RPN) is obtained by multiplying these factors. There are significant efforts which have been made in FMEA literature to overcome the shortcomings of the crisp RPN calculation. In this study a fuzzy approach, allowing experts to use linguistic variables for determining S, O, and D, is considered for FMEA by applying fuzzy ‘technique for order preference by similarity to ideal solution’ (TOPSIS) integrated with fuzzy ‘analytical hierarchy process’ (AHP). The hypothetical case study demonstrated the applicability of the model in FMEA under fuzzy environment.     

Failure mode and effects analysis using intuitionistic fuzzy hybrid weighted Euclidean distance operator

Failure mode and effects analysis (FMEA) has shown its effectiveness in examining potential failures in products, process, designs or services and has been extensively used for safety and reliability analysis in a wide range of industries. However, its approach to prioritise failure modes through a crisp risk priority number (RPN) has been criticised as having several shortcomings. The aim of this paper is to develop an efficient and comprehensive risk assessment methodology using intuitionistic fuzzy hybrid weighted Euclidean distance (IFHWED) operator to overcome the limitations and improve the effectiveness of the traditional FMEA. The diversified and uncertain assessments given by FMEA team members are treated as linguistic terms expressed in intuitionistic fuzzy numbers (IFNs). Intuitionistic fuzzy weighted averaging (IFWA) operator is used to aggregate the FMEA team members’ individual assessments into a group assessment. IFHWED operator is applied thereafter to the prioritisation and selection of failure modes. Particularly, both subjective and objective weights of risk factors are considered during the risk evaluation process. A numerical example for risk assessment is given to illustrate the proposed method finally.     

结合OWA算子和模糊DEMATEL的风险评估方法

针对传统故障模式与影响分析(FMEA)方法在实际应用中的不足,提出一种基于有序加权平均(OWA)算子和决策试行与评价实验法(DEMATEL)的风险排序方法。FMEA专家对故障模式的3个风险因子给出模糊评价信息,应用OWA算子对评估信息进行集结,得到各故障原因对故障模式的影响强度。采用模糊DEMATEL法构建FMEA系统要素间的初始直接影响矩阵,经过运算可得综合影响矩阵,并计算各故障原因的原因度,据此进行产品或系统的失效风险评估。运用该方法对地铁车门系统的基础部件进行安全性分析,并将所得结果与传统RPN方法的结果做对比,验证了该方法的可行性和有效性。     

Fuzzy FMEA application to improve decision-making process in an emergency department

Hospitals are one of the important service industries of health care for patients. The emergency department is the heart of every hospital, because the errors or failures occurring in it will significantly affect the safety of patients and the goodwill of the hospital. Therefore, emergency departments should be monitored carefully. This study proposed the application of Fuzzy failure mode and effects analysis (FMEA) for prioritization and assessment of failures that likely occur in the working process of an emergency department. All individuals were assessed independently without the interference of team members. In addition, this method could reduce the limitations of traditional FMEA. The prioritization of risks could also help the emergency department to choose corrective actions wisely. In conclusion, the Fuzzy FMEA method was found to be suitably adopted in the emergency department. Finally, this method helped to increase the level of confidence on hospitals.     

Failure mode and effects analysis using a group-based evidential reasoning approach

Failure mode and effects analysis (FMEA) is a methodology to evaluate a system, design, process or service for possible ways in which failures (problems, errors, risks and concerns) can occur. It is a group decision function and cannot be done on an individual basis. The FMEA team often demonstrates different opinions and knowledge from one team member to another and produces different types of assessment information such as complete and incomplete, precise and imprecise and known and unknown because of its cross-functional and multidisciplinary nature. These different types of information are very difficult to incorporate into the FMEA by the traditional risk priority number (RPN) model and fuzzy rule-based approximate reasoning methodologies. In this paper we present an FMEA using the evidential reasoning (ER) approach, a newly developed methodology for multiple attribute decision analysis. The proposed FMEA is then illustrated with an application to a fishing vessel. As is illustrated by the numerical example, the proposed FMEA can well capture FMEA team members’ diversity opinions and prioritize failure modes under different types of uncertainties.     

A fuzzy rough number extended AHP and VIKOR for failure mode and effects analysis under uncertainty

Failure mode and effects analysis (FMEA) is one of the most popular reliability analysis techniques due to its outstanding capabilities in identifying, assessing, and eliminating potential failure modes in a wide range of industrial applications. It provides a comprehensive view for investigating potential failures, causes, and effects in designs, products, and processes. However, traditional FMEA is extensively criticized for its defects in determining the criteria weights, identifying the risk priority of failure modes, and handling the uncertainty during the risk evaluation. To resolve these problems, this study proposes a novel fuzzy rough number extended multi-criteria group decision-making (FR-MCGDM) strategy to determine a more rational rank of failure modes by integrating the fuzzy rough number, AHP (analytic hierarchy process), and VIKOR (Serbian: VIseKriterijumska Optimizacija I Kompromisno Resenje). Above all, a fuzzy rough number is introduced to characterize experts’ judgment, aggregate group risk assessments, and tackle the uncertainty and subjectivity in the risk evaluation. Then a fuzzy rough number enhanced AHP is presented to determine the criteria weights. A fuzzy rough number enhanced VIKOR is proposed to rank the failure modes. A practical case study of the check valve is provided to validate the applicability of the proposed FMEA. Comparative studies demonstrate the efficacy of the proposed FR-MCGDM, with remarkable advantages in handling the uncertainty and subjectivity during failure modes evaluation.     

Failure mode and effects analysis using D numbers and grey relational projection method

Failure mode and effects analysis (FMEA) is a widely used risk assessment tool for defining, identifying and eliminating potential failures or problems in products, process, designs and services. Two critical issues of FMEA are the representation and handling of various types of assessments and the determination of risk priorities of failure modes. Many different approaches have been suggested to enhance the performance of traditional FMEA; however, deficiencies exist in these approaches. In this paper, based on a more effective representation of uncertain information, called D numbers, and an improved grey relational analysis method, grey relational projection (GRP), a new risk priority model is proposed for the risk evaluation in FMEA. In the proposed model, the assessment results of risk factors given by FMEA team members are expressed and modeled by D numbers. The GRP method is used to determine the risk priority order of the failure modes that have been identified. Finally, an illustrative case is provided to demonstrate the effectiveness and practicality of the proposed model.     

Evaluating the risk of failure using the fuzzy OWA and DEMATEL method

Most current risk assessment methods use the risk priority number (RPN) value to evaluate the risk of failure. However, traditional RPN methodology has been criticized to have several shortcomings. Therefore, an efficient, simplified algorithm to evaluate the orderings of risk for failure problems is proposed in this paper, which utilizes fuzzy ordered weighted averaging (OWA) and the decision making trial and evaluation laboratory (DEMATEL) approach to rank the risk of failure. The proposed approach resolves some of the shortcomings of the traditional RPN method. In numerical verification, a failure mode and effects analysis (FMEA) of the thin film transistor liquid crystal display (TFT-LCD) product is presented to further illustrate the proposed approach. The results show that the proposed approach can reduce duplicated RPN numbers and get a more accurate, reasonable risk assessment. As a result, the stability of product and process can be assured.     

Fuzzy modeling of system behavior for risk and reliability analysis

The main objective of the article is to permit the reliability analyst's/engineers/managers/practitioners to analyze the failure behavior of a system in a more consistent and logical manner. To this effect, the authors propose a methodological and structured framework, which makes use of both qualitative and quantitative techniques for risk and reliability analysis of the system. The framework has been applied to model and analyze a complex industrial system from a paper mill. In the quantitative framework, after developing the Petrinet model of the system, the fuzzy synthesis of failure and repair data (using fuzzy arithmetic operations) has been done. Various system parameters of managerial importance such as repair time, failure rate, mean time between failures, availability, and expected number of failures are computed to quantify the behavior in terms of fuzzy, crisp and defuzzified values. Further, to improve upon the reliability and maintainability characteristics of the system, in depth qualitative analysis of systems is carried out using failure mode and effect analysis (FMEA) by listing out all possible failure modes, their causes and effect on system performance. To address the limitations of traditional FMEA method based on risky priority number score, a risk ranking approach based on fuzzy and Grey relational analysis is proposed to prioritize failure causes.     

A more general risk assessment methodology using a soft set-based ranking technique

Process failure mode and effects analysis (PFMEA) is used in the high-tech industry to improve a product’s quality and robustness. It is not only an important risk assessment technique but also a valuable task for implementing production management. Its main purpose is to discover and prioritize potential failure modes. Most of the current PFMEA techniques use the risk priority number (RPN) value to evaluate the risk of failure. However, the traditional RPN methodology has a serious problem with regard to measurement scales, does not consider the direct and indirect relationship between potential failure modes and causes of failure, and loses potentially valuable expert-provided information. Moreover, there are unknown, partially known, missing, or nonexistent data identified during the process of collecting data for PFMEA; this increases the difficulty of risk assessment. Issues with incomplete information cannot be fully addressed using the traditional RPN methodology. In order to effectively address this problem, the current paper proposes a novel soft set-based ranking technique for the prioritization of failures in a product PFMEA. For verification of the proposed approach, a numerical example of the Xtal unit PFMEA was adopted. This study also compares the results of the traditional RPN and DEMATEL methods for dealing with incomplete data. The results demonstrate that the proposed approach is preferable for reflecting actual stages of incomplete data in PFMEA. As a result, product and process robustness can be assured.     

Exploiting 2-tuple linguistic representational model for constructing HOQ-based failure modes and effects analysis

Failure modes and effects analysis (FMEA) is a widely recognized tool used to identify potential failure risks for improving the reliability and safety of new products. A major function of FMEA is to evaluate, analyze, and determine the risk priority number (RPN) of each potential failure mode based on three risk assessment indices: severity, occurrence, and detectability in order to eliminate the potential risk. Unlike in conventional practice, where these indices are measured using discrete ordinal scales, this study adopts a 2-tuple linguistic computational approach to treat the assessments of the three risk indices and develop an FMEA assessment model to overcome the drawbacks of conventional RPN calculation. The house of quality (HOQ), a central tool of quality function deployment, is adopted to determine the more reasonable evaluations of the occurrence and detectability indices. The three risk indices are considered with different weights in the proposed model to obtain RPNs. Compared to conventional and fuzzy FMEA, the proposed FMEA model is more useful for determining practical RPNs for risk analysis and management in new product development (NPD). An example is used to demonstrate the applicability of the proposed model.     

Evaluating the risk of healthcare failure modes using interval 2-tuple hybrid weighted distance measure

Failure mode and effects analysis (FMEA), as a usefulness and powerful risk assessment tool, has been widely utilized in different industries for improving the safety and reliability of systems. However, the conventional risk priority number (RPN) method shows some important weaknesses when applied in actual situations. Moreover, FMEA is a group decision behavior and FMEA team members tend to use different linguistic term sets to express their judgments because of their different backgrounds and preferences, some of which may be imprecise, uncertain and incomplete. In this paper, we propose a new risk priority model using interval 2-tuple hybrid weighted distance (ITHWD) measure to solve the problems and improve the performance of the traditional FMEA. The new model can not only handle the uncertainty and diversity of FMEA team members’ assessment information but also consider the subjective and objective weights of risk factors in the risk ranking process. The model has exact characteristic and can avoid information distortion and loss in the linguistic information processing. Finally, a case study of blood transfusion is provided to demonstrate the effectiveness and benefits of the proposed approach.     

Identifying and evaluating enterprise architecture risks using FMEA and fuzzy VIKOR

Enterprise architecture (EA) is an approach for managing all components of enterprise and relationships among them. By implementing EA, the organization will be threatened from different aspects. We used failure mode and effect analysis (FMEA) which is a powerful tool for evaluating EA risks. In traditional FMEA, risk priority number (RPN), has been calculated by multiplication of three criteria, severity, occurrence and detection. Because of some drawbacks of the traditional FMEA, this paper—instead of calculating RPN—prioritizes EA risk factors with fuzzy VIKOR. VIKOR (VlseKriterijumska Optimizacija I Kompromisno Resenje in Serbian, means Multi-criteria Optimization and Compromise Solution) is a multiple attribute decision making technique which aims to rank EA risk factors with respect to the criteria. As regards using linguistic variables, fuzzy approach is used to allow experts to use linguistic variables. The proposed method is used for evaluating twenty EA risk factors, which integrates knowledge and experience acquired from professional experts.     

Failure Mode and Effects Analysis Based on Z-numbers

The main objective of this paper is to propose a new method for failure mode and effects analysis (FMEA) based on Z-numbers. In the proposed method, firstly, Z-numbers are used to perform the valuations (Z-valuation) of the risk factors like occurrence (O), severity (S) and detection (D). Secondly, the Z-valuations of the risk factors are integrated by fuzzy weighted mean method. A new risk priority number named as ZRPN is calculated to prioritize failure modes based on a modified method of ranking fuzzy numbers. Finally, a case study for the rotor blades of an aircraft turbine is performed to demonstrate the feasibility of the proposed method.     

Risk evaluation approaches in failure mode and effects analysis: A literature review

Failure mode and effects analysis (FMEA) is a risk assessment tool that mitigates potential failures in systems, processes, designs or services and has been used in a wide range of industries. The conventional risk priority number (RPN) method has been criticized to have many deficiencies and various risk priority models have been proposed in the literature to enhance the performance of FMEA. However, there has been no literature review on this topic. In this study, we reviewed 75 FMEA papers published between 1992 and 2012 in the international journals and categorized them according to the approaches used to overcome the limitations of the conventional RPN method. The intention of this review is to address the following three questions: (i) Which shortcomings attract the most attention? (ii) Which approaches are the most popular? (iii) Is there any inadequacy of the approaches? The answers to these questions will give an indication of current trends in research and the best direction for future research in order to further address the known deficiencies associated with the traditional FMEA.     

Reprioritization of failures in a silane supply system using an intuitionistic fuzzy set ranking technique

Most of the current failure mode, effects, and criticality analysis (FMECA) methods use the risk priority number (RPN) value to evaluate the risk of failure. However, the traditional RPN methodology has been criticized to have several shortcomings. These shortcomings are addressed in this paper. Therefore, an efficient and simplified algorithm to evaluate the risk of failure is needed. This paper proposes a new approach, which utilizes the intuitionistic fuzzy set ranking technique for reprioritization of failures in a system FMECA. The proposed approach has two major advantages: (1) it resolves some of the shortcomings of the traditional RPN method, and (2) it provides an evaluation of the redundancy place, which can assist the designer in making correct decisions to make a safer and more reliable product design. In numerical verification, an FMECA of a silane supply system is presented as a numerical example. After comparing results from the proposed method and two other approaches, this research found that the proposed approach can reduce more duplicate RPN numbers and get a more accurate, reasonable risk ranking.     

A perceptual computing-based method to prioritize failure modes in failure mode and effect analysis and its application to edible bird nest farming

A failure mode and effect analysis (FMEA) procedure that incorporates a novel Perceptual Computing (Per-C)–based Risk Priority Number (RPN) model is proposed in this paper. The proposed model considers linguistic uncertainties and vagueness of words, because it is more natural to use words, instead of numerals, for an FMEA user to express his/her knowledge when he/she provides an assessment. Therefore, it is important to consider the inherited uncertainties in words used by humans for assessment as an additional risk factor in the entire FMEA reasoning process. As such, we propose to use Per-C to analyze the uncertainties in words provided by different FMEA users. There are three potential sources of risks. Firstly, the risk factors of Severity (S), Occurrence (O), and Detection (D) are graded using words by each FMEA user, and indicated as interval type-2 fuzzy sets (IT2FSs). Secondly, the relative importance of S, O, and D are reflected by the weights given by each FMEA user in words, which are indicated as IT2FSs. Thirdly, the expertise level of each FMEA user is reflected by words, which are expressed as IT2FSs too. The proposed Per-C-RPN model allows these three sources of risks from each FMEA user to be considered and combined in terms of IT2FSs. A case study related to edible bird nest farming in Borneo Island is reported. The results indicate the effectiveness of the proposed model. In summary, this paper contributes to a new Per-C-RPN model that utilizes imprecise assessment grades pertaining to group decision making in FMEA.