The Challenge of Deploying Failure Modes and Effects Analysis in Complex System Applications—Quantification and Analysis

Abstract

Failure Modes and Effects Analysis (FMEA) is a systematic approach for evaluating failure modes in a system. However, its current implementation in complex systems is marred by high resource requirements, a lack of available data and difficulty of deployment. Consequently, attempts to integrate FMEA with other systematic methodologies have yielded unclear outcomes. Therefore, this paper used a score-based metric and applied the ordered probit model to empirically identify challenges associated with deploying FMEA and these attempts’ impact on FMEA applications as well as the influence of other organisational parameters. Our findings reveal that Fault Tree Analysis and Axiomatic Design methodologies reduced the perceived level of challenge significantly in the investigated sample. Our research outcome is of value to the practitioner community by showing that the level of challenge associated with FMEA deployment appears independent of organisational parameters, and that such a co-adoption of complementary methodologies in complex systems can reduce this challenge.

Model‐Based FMEA & FTA with Case‐Based Reasoning

“…In a simplified systems architecture, knowledge management is relatively easier and more straightforward, and the organization can usually rely on a relatively small number of team members who can perform both system architecture and safety and reliability analysis. However, in a complex systems architecture, knowledge management needs to be more systematic and capture information from diverse and multi-disciplinary teams (Alruqi et al 2022).…”

“…2. Utilize the knowledge from historical data and systems architecture: MBSE, historical data, and SysML systems architecture provides a systematic way to capture, reuse, and adapt the safety & reliability knowledge, which can be helpful for next-generation product development (Alruqi et al 2022).…”

“…However, in practice, the linkage/relationships among safety & reliability methods are difficult to trace and establish manually in a multi-disciplinary and diverse team. Moreover, the size and complexity of the system and risk analysis models have increased the issues (Alruqi et al 2022).…”