Failure mode and effects analysis using function–motion–action decomposition method and integrated risk priority number for mechatronic products

Abstract

Failure mode and effects analysis is a widely applied risk assessment method in various engineering and management domains. However, the identification of failure modes is difficult and uncountable. Therefore, a function-motion-action (FMA) decomposition method is developed to identify failure modes from the perspective of motion and extraordinarily suitable for mechatronic products. In the typical risk assessment, the ranking orders of failure modes are determined by risk priority number (RPN), which has been criticized for several drawbacks and improved by some alternative RPNs, but some drawbacks still exist, such as duplicate values, narrow admissible value range, and missing failure modes' and risk factors' weights. This study formulates several alternative weighted RPNs to overcome the above drawbacks, and the final ranking orders of failure modes are garnered through the integrated RPN (IRPN). First, failure modes are identified via the proposed FMA decomposition method and evaluated with crisp values, whose weights are aggregated from the basic failure modes' weights. Second, the weights of the basic failure modes, risk factors and different RPN methods are derived from analytic hierarchy process. Third, the conditional weights of risk factors are determined by incorporating risk factors' weights and failure modes' conditional weights deduced from Shannon entropy. Next, several alternative weighted RPNs and IRPN are formulated to rank failure modes' risk levels. Finally, an illustrative example about computer numerical control machine center is presented to demonstrate the application and effectiveness of the proposed method.

Evaluating the academic scientific laboratories' safety by applying failure mode and effect analysis (FMEA) at the public university in Lebanon

“…It was difficult to make a direct comparison of the scores of FMs because of the lack of studies quantifying the RPNs scores using FMEA analysis in academic research laboratory settings. The mathematical accuracy of calculating RPN score values has been a concern for researchers as well and it is a known limitation of FMEA [ 24 , 35 , [40] , [41] , [42] , [43] ]. Subjectivity and inability to generalize the results are other limitations of this study, they are as also reported in another study [ 24 ].…”

Analysis Of Quality Control of Defects In 500 Ml Plastic Bottle Products Using Fault Tree Analysis and FMEA Methods At PT. Berlina Tbk Pandaan

“…This is influenced by a reason: the type of plastic pellets is unsuitable due to the different melting rates of the plastic pellets. Analysis FMEA (Failure Mode and Effect Analysis) According to [12] and [13], the RPN (Risk Priority Number) value is determined using data from FMEA (Failure Mode and Effect Analysis) analysis in order from largest to smallest. Following are the findings of an FMEA (Failure Mode and Effect investigation) investigation into errors in 500 ml plastic bottle packaging related to material, oil impurities, and folding: 1.…”

Analysis of sag mill machine performance using overall equipment effectiveness and failure model and effects analysis method

“…These machines often suffer damage making targets and not achieving product quality. According to research by Pholmeyer (2022) [15], the study presents an approach for a data-driven failure risk assessment validated on real-world process data of a nonwoven production line. In this approach, association rule mining applies to continuous processes for producing highly interpretable results in the primary causes of failures.…”

“…By using OEE and FMEA in live production, causes of failures can be detected and interpreted. Based on previous research conducted by Wang (2021) [16]. The primary purpose of the FMEA in this paper is to identify potential effects and rank them according to their severity.…”