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Failure modes and effects analysis (FMEA) is a quality improvement and risk assessment tool commonly used in industry. It is a living document used to capture design and process failure information. However, the traditional FMEA has its limitations in terms of knowledge capture and reuse. In order to increase its effectiveness, much research has be...
Citations
... For the purpose of this paper-the consideration of risk early in design-the relevant approaches are those which enable designers to design for risk using a functional model. While many modelling approaches for this task have been presented (see: [11] [12], [13], [14], [15], [16]), little has been done to present the process to then incorporate this information in design. [17] presents a human-in-theloop approach in which the designer identifies failure paths using a visualization given by the fault propagation software. ...
Due to the expansive, time-consuming nature of risk analyses, it is important to be able to assign the minimization of risk (and, in general, optimization of resilience) to responsible teams that can work in parallel. However, while methods exist for minimization of risk in conventional design processes, research has not yet shown how it should be performed in a model-based design context in early design phase, when the design representation is relatively high-level and there are uncertainties in parameter values. This paper presents a value-driven design approach to minimize risk by decomposing the design, operational, and expected failure costs to individual functions in a system failure model. This process is demonstrated in a case study considering the redundancy of components to fulfill overall functions in an electric power system, where it is shown to increase design value significantly. An uncertainty-based process is additionally provided to enable the designer to test the sensitivity of the chosen design solution to uncertain parameter values. In this limited case study it is shown that the sensitivity of the choice to parameter value uncertainty is low, provided the range of uncertainty for each parameter is within a reasonable range. In situations like this, presented expected cost metrics provide meaningful information to justify system-architectural design decisions made on the basis of resilience.
... FMEA is useful in providing insights for making risk management decisions and in improving the overall performance of the system (Pillay and Wang, 2003;Chen and Ko, 2009). FMEA is powerfully developed, and emerged as a failure/problem/source analysis technique, and widely used by engineers and system managers in different areas such as quality improvement, safety & reliability analysis, manufacturing, service, etc. ( Teoh and Case, 2004;Chuang, 2007;Kumru and Kumru, 2013). In classical FMEA in evaluating risks, failure mean/mode is estimated in the form of RPNs. ...
Purpose
This contribution aims to facilitate Green Supply Chain (GSC) managers and planners to model and access GSC risks and probable failures. This paper proposes to use the fuzzy FMEA approach for assessing the risks associated with GSC for benchmarking the performance in terms of effective GSC management adoption and sustainable production.
Design/methodology/approach
Initially, different failure modes are defined using FMEA analysis, and in order to decide the risk priority, the risk priority number (RPN) is determined. Such priority numbers are typically acquired from the judgment decisions of experts that could contain the element of vagueness and imperfection due to human biases, and it may lead to inaccuracy in the process of risk assessment in GSC. In this study, fuzzy logic is applied to conventional FMEA to overcome the issues in assigning risk priority numbers. A plastic manufacturer GSC case exemplar of the proposed model is illustrated to present the authenticity of this method of risk assessment.
Findings
Results indicates that the failure modes, given as Improper green operating procedure i.e. process, operations, etc (R6) and Green issues while closing the loop of GSC (R14) hold the highest RPN and FRPN scores in classical as well as fuzzy FMEA analysis.
Originality/value
The present research work attempts to propose an evaluation framework for risk assessment in GSC. This paper explores both sustainable developments and risks related to efficient management of GSC initiatives in a plastic industry supply chain context. From a managerial perspective, suggestions are also provided with respect to each failure mode.
... To solve the fundamental question of ranking, the final fuzzy criticality value, a particular method of classification is suggested for a fast and efficient sorting of the final outcome. An application to an important Italian domestic appliance manufacturer and a comparison with conventional FMECA are reported to demonstrate the characteristics of the proposed method are discussed Teoh and Case (2004) found that FMEA was a quality improvement and risk assessment tool, commonly used in industry. They reviewed various FMEA research studies, modelling and reasoning methods that could be used for generic applications. ...
FMEA is a systematic method of identifying and preventing system, product and process problems before they occur. It is focused on preventing problems, enhancing safety, and increasing customer satisfaction. Formally FMEA was introduced in the late 1940s by the US military Forces. In 1960s it was used by the aerospace industry as a design methodology, with their obvious reliability and safety requirements. In the late 1970s, the Ford Motor Company introduced FMEA to the automotive industry for safety and regulatory consideration. They also used it to improve production and design.FMEA is widely used in manufacturing industries in various phases of the product life cycle and it now extensively used in a variety of industries including semiconductor processing, food service, plastics, power plant, software, and healthcare. A successful FMEA activity enables a team to identify potential failure modes based on past experience with similar products or processes, enabling the team to design those failures out of the system with the minimum of effort and resource expenditure, thereby reducing development time and costs. This paper highlights the various approaches and applications of FMEA have been developed so far.
... Other approaches focusing on teleological modeling in engineering design are also available. Models like Function-Behavior-Structure [23,24], Structure, Behavior, and Function [25], Function-Behavior-State [56][57][58], and functional diagram [54] all treat functions as critical components in the design thinking and provide conceptual approaches to organize the various mappings among functions, behaviors, structures, states, etc. For instance, function diagram in Teoh and Case [54] are used to represent function and structure interactions with a network connected by multiple function units, which is defined as function operator -function ?function operand, i.e. a verb or verb phrase that defines the action and connects two objects (function operator and function operand). ...
... Models like Function-Behavior-Structure [23,24], Structure, Behavior, and Function [25], Function-Behavior-State [56][57][58], and functional diagram [54] all treat functions as critical components in the design thinking and provide conceptual approaches to organize the various mappings among functions, behaviors, structures, states, etc. For instance, function diagram in Teoh and Case [54] are used to represent function and structure interactions with a network connected by multiple function units, which is defined as function operator -function ?function operand, i.e. a verb or verb phrase that defines the action and connects two objects (function operator and function operand). ...
With the advances in CAD technology, it has been increasingly convenient to model product shapes digitally. For example, in a feature-based parametric CAD system, the product shape could be parameterized and thus altered with the change of parameters. However, without a consistent and systematic CAD mod-eling method, CAD models are not robust enough to capture functional design knowledge and cope with design changes, especially functional changes. A poorly constructed CAD model could result in erroneous or inconsistent design that requires a lot of expertise, manpower and repetitive computation to rebuild a valid and consistent model. The situation can be worse if the model is complex. The gap between functional design considerations and procedural CAD modeling demands an integrated CAD modeling approach. This paper proposes a functional feature-based CAD modeling method to guide designers building CAD models that are valid and yet agile to represent functional design considerations. A case study is presented to demonstrate the feasibility of the proposed research.
... Chandrasekaran and Josephson (2000) modelled function as effects in a device-centric view, that is, an intended or desired role that an artefact plays in its environment. Teoh and Case (2004) introduced the concept of functional diagram to represent function and structure interaction, which is a network connected by multiple function units. Two objects, function operator and function operand, are linked by a function, which takes the form of a verb or verb phrase that defines the action, to form a function unit in the form of function operator -function → function operand. ...
This paper presents a generic functional design modelling methodology applied in the computer-aided design (CAD) environment to associate functional considerations and physical models of the design. Function concept modelling represents the engineering design purposes of the product elements and is usually considered to be interdependent from the detailed geometric solutions. Although CAD is prevailing in modelling geometry of the design artefacts, functional considerations, or design intents, are often not represented systematically and explicitly. The gaps between functional and geometrical representations of the design models require an extensive research to unveil their associations and interactions. Functional feature, and the corresponding semantic representation with the built-in mechanisms, is proposed in this paper to support a CAD methodology that models the interrelations between functional and physical considerations of the design and drives the design through functional perspective. Abstract geometry features are used as functional concept carriers with certain geometries to link functional design considerations in the detailed design model. A case study of a designed product that is used in the oil extraction process from oil sands in Canada is presented to demonstrate the feasibility of the proposed methodology.
... A risk matrix between probability of occurrence and severity is then used to select the failure modes. Teoh explained modeling and reasoning method for FMEA generation [10]. He showed that function decomposition can be achieved by the flow-based approach including the integrated definition (IDEF) method and a functional diagram approach. ...
This paper describes quality risk analysis in the dispensing center where all required medical substances of each formula are weighted, checked, and verified before transferring to the production line. Like any working station, risk in terms of both information and operations can take place here. Thus, all of these risk opportunities must be identified and evaluated and the possible prevention and protection measures must be devised to avoid these risks. Based on the analysis in the case study in this paper, there are a number of potential risks and four of them are shortlisted with recommended alleviation actions. Index Terms—FMEA in pharmaceutical, FMECA, pharmaceutical dispensing center, quality risk management.
... What would be the consequences of each failure? The success of FMEA depends on good forecast conception of failure reasons either the manufacturing process or manufacturing machine [1]. ...
The paper deals with problems of the collision states monitoring in mass
production process with potential environmental impact. The flexographic and
rotogravure printing machines for plastic packaging flexible foils production are
the objects of monitoring, mainly the drying technological sections. The paper is
focused on the usage of vibration diagnostics of rotational equipment, i.e.
ventilators in dryers. The selection of appropriate on-line system control by way
of intelligent component implementation is a critical problem of mass production
with dangerous operation. The project of monitoring system application is
described. The new system of automatic monitoring regime with the use of
artificial intelligence elements was projected and tested.
Keywords: emissions, bearing failure, envelope analysis, vibration monitoring.
... Early researches on traditional FMEA were classified into design failure mode and effect analysis (DFMEA) and process FMEA. Out of these, DFMEA deals with product design, and process FMEA solves problems due to manufacturing (Inoue and Yamada, 2010;Teoh and Case, 2004a) supporting the later stages of product development (Aldridge et al., 1991). The use of FMEA along with other quality tools such as fuzzy, quality function development (QFD), FTA is also evident to attain continuous quality improvement (Regazzoni and Russo, 2011;Teng and Ho, 1996). ...
... In today's competitive business scenario FMEA has become mandatory to hold and run business, helping the organisations in applying and finding failure models and corrective actions to reduce the potential of occurrence (Brown et al., 2008;Segismundo and Miguel, 2008;Sharma et al., 2007). The findings are that traditional FMEA is not exhaustive and therefore does not facilitate the prevention of failures holistically (Aldridge et al., 1991;Chapman et al., 2011;Ho and Liao, 2011;Slinger, 1992;Teoh and Case, 2004a). To overcome this, few researchers have developed advanced models of FMEAs (Pillay and Wang, 2003;Xiao et al., 2011). ...
In the recent past, researchers and practitioners have been attempting failure prevention as one of the major enablers of attaining continuous quality improvement. For this, failure mode and effect analysis (FMEA) technique is adopted to reduce the probability of system failure and achieve good product quality. However, there has been no significant effort made by the researchers to overcome the pitfalls of FMEA. This practical gap is overcome by applying a technique called total failure mode and effect analysis (TFMEA). This research gap has been indicated and explored further by conducting literature review to draw synergy out of TFMEA along with the unconquered areas of the TFMEA, where TFMEA can be applied. A roadmap for implementing TFMEA has also been contributed in this paper.
... The models representing normal behavior of the target system and/or functional structures are used for automatic FMEA generation such as AFMEA [27] and FMAG [28], model-based diagnosis [29][30] and fault identification and propagation [31] [32]. These models can automatically deduce the effect-propagation of a functional defect along with the behavioral/functional structure. ...
This paper proposes a holistic teleology-based modeling framework for product-related processes named FOREST. Several processes such as functioning processes, fault-related processes and manufacturing processes can be represented as goal-oriented process trees in the three-dimensional space as an extension of an ontology-based functional modeling framework. One of the expected benefits is to help engineers externalize their process knowledge extensively from several aspects in a comprehensive manner. In this paper, we demonstrate its effect in enumerating fault processes by showing the result of an industrial experiment.
... According to Johnson (2002) Pillay and Wang (2003) Chin et al (2009) FMEA is a method which shows and evaluates the potential failure of a process. This method which is widely used in industry, service and etc,ranks such potential failures and helps managers omit them(Sankar and Prabhu,2001;Nakajima et al,2002;Price and Taylor,2002;Scipioni et al,2002;Xu et al,2002;Rhee and Ishii ,2003;Guimaraes and Lapa,2004,2007;Teoh and Case,2004;Almannai et al,2008;Su and chou ,2008) In this method we check all components of our important process to identify possibility failure. Some factors such as price, goals, costs and etc must be considered when analyzing FMEA (Trammell et al, 2004). ...
All organizations look forwards to evaluate themselves. There are a lot of methods for such an evaluation. One popular method is Balanced Scorecard which evaluates an organization from four perspectives. This method is shows in which of the four perspectives, an organization is weak or strong. However, this method has some weaknesses. One of them is that managers do not know which performance driver has a higher priority over others. Such negligence may lead to the loose of markets and customers. The aim of this paper is to find the problem and rank by the risk by fuzzy FMEA.Fuzzy FMEA has shown the risk score of each items by RPN.In this paper we have combined BSC and Fuzzy FMEA methods to introduce a new method for ranking performance drivers and to find out which of the performance drivers has higher priority based on risk factors occurrence (O), severity (S) and detection (D).Also we design improvement projects for high priority risks which are found by Fuzzy FMEA and then we allocate our limited resources to them. This method can help increase the customer satisfaction and design the best improvement projects to reach to our vision. This method performance in Sepehr safety glass
