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Assessing the severity of failure modes of critical industrial machinery is often considered as an onerous task and sometimes misinterpreted by shop-floor engineer/maintenance personnel. The purpose of this paper is to develop an improved FMECA method for prioritizing the failure modes as per their risk levels and validating the same through a real case study of induction motors used in a process plant.

This paper presents a novel hybrid multi-criteria decision-making (MCDM) approach to prioritize different failure modes according to their risk levels by combining analytical hierarchy process (AHP) with a newly introduced MCDM approach, election based on relative value distance (ERVD). AHP is incorporated in the proposed approach to determine the criteria weights, evaluated in linguistic terms by industrial expert. Furthermore, ERVD, which is based on the concept of prospect theory of human cognitive process, is applied to rank the potential failure modes.

It is found that the proposed FMECA approach provides better results in accordance with the actual industrial scenario and helps in effectively prioritizing the failure modes. A comparison is also made to highlight the differences of results between the proposed approach with TOPSIS and conventional FMECA.

This research paper proposes an improved FMECA method and, thus, provides a deep insight to maintenance managers for effectively prioritizing the failure modes. The correct prioritization of failure modes will help in effective maintenance planning, thus reducing the downtime and improving profit to the organization.

A real case of process plant induction motor has been introduced in the research paper to show the applicability of this decision-making approach, and the approach is found to be suitable in correct prioritization of the failure modes.

Severity has been decoupled into various factors affecting it, to make it more relevant as per actual industrial scenario. Then, a novel modified FMECA has been developed using a hybrid MCDM approach (AHP and ERVD). This hybrid method, as well as its application in FMECA, has not been developed by any previous researcher. Moreover, the same has been thoroughly explained by considering a real case of process plant induction motors and validated with cross-functional experts.

The purpose of this paper is to establish the damage alarming indexes for ancient wood structures and study the damage sensitivity and noise robustness of these indexes under random excitation.

Xi’an Bell Tower is taken as a case in this paper to simulate the damage of ancient wood structures through finite element (FE) simulation and determine the satisfactory damage alarming indexes with wavelet packet energy spectrum.

The results of this paper show that: 1) the damage alarming indexes can effectively identify the damage of ancient wood structures, each index with a different damage sensitivity; 2) the energy ratio deviation is greater than the energy ratio variance and is close to the maximum variation of energy ratio; 3) the energy ratio deviation has a better alarming effect than the energy ratio variance during the initial period of the damage. With the accumulation of the damage, the energy ratio variance outperforms the energy ratio deviation; 4) the sensitivity of the energy ratio deviation and variance varies from positions, changing from the highest to lowest at the mortise-and-tenon joints, the beam mid-span and the plinth; 5) if signal to noise ratio (SNR) is 40db or larger, the indexes can accurately identify the damage of ancient wood structures. As SNR increases, the indexes will have an increasingly higher sensitivity and certain ability to resist noise.

The FE model is simpiy, it does not completely reflect Xi’an Bell Tower.

It will provide a theoretical basis for the damage alarming of Xi’an Bell Tower.

It makes structural health monitoring through structural vibration response under ambient excitation a new research field in damage detection as well as a positive way of ancient architecture protection.

This paper studies the damage alarming effect on ancient wood structures from different wavelet functions and wavelet packet decomposition levels. To study the effect under white noise environment, this paper adds Gaussian white noise with a SNR of 10, 20, 30, 40 and 50 db to the acceleration response signal of intact structure and damaged structure.