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Article
Publication date: 17 April 2007

Wei‐Jaw Deng, Chung‐Ching Chiu and Chih‐Hung Tsai

Failure mode and effects analysis (FMEA) is a preventive technique in reliability management field. The successful implementation of FMEA technique can avoid or reduce the…

Abstract

Failure mode and effects analysis (FMEA) is a preventive technique in reliability management field. The successful implementation of FMEA technique can avoid or reduce the probability of system failure and achieve good product quality. The FMEA technique had applied in vest scopes which include aerospace, automatic, electronic, mechanic and service industry. The marking process is one of the back ends testing process that is the final process in semiconductor process. The marking process failure can cause bad final product quality and return although is not a primary process. So, how to improve the quality of marking process is one of important production job for semiconductor testing factory. This research firstly implements FMEA technique in laser marking process improvement on semiconductor testing factory and finds out which subsystem has priority failure risk. Secondly, a CCD position solution for priority failure risk subsystem is provided and evaluated. According analysis result, FMEA and CCD position implementation solution for laser marking process improvement can increase yield rate and reduce production cost. Implementation method of this research can provide semiconductor testing factory for reference in laser marking process improvement.

Details

Asian Journal on Quality, vol. 8 no. 1
Type: Research Article
ISSN: 1598-2688

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Article
Publication date: 10 May 2019

Fatemeh Shaker, Arash Shahin and Saeed Jahanyan

The purpose of this paper is to propose an integrative approach for improving failure modes and effects analysis (FMEA).

Abstract

Purpose

The purpose of this paper is to propose an integrative approach for improving failure modes and effects analysis (FMEA).

Design/methodology/approach

An extensive literature review on FMEA has been performed. Then, an integrative approach has been proposed based on literature review. The proposed approach is an integration of FMEA and quality function deployment (QFD). The proposed approach includes a two-phase QFD. In the first phase, failure modes are prioritized based on failure effects and in the second phase, failure causes are prioritized based on failure modes. The proposed approach has been examined in a case example at the blast furnace operation of a steel-manufacturing company.

Findings

Results of the case example indicated that stove shell crack in hot blast blower, pump failure in cooling water supply pump and bleeder valves failed to operate are the first three important failure modes. In addition, fire and explosion are the most important failure effects. Also, improper maintenance, over pressure and excess temperature are the most important failure causes. Findings also indicated that the proposed approach with the consideration of interrelationships among failure effects, failure mode and failure causes can influence and adjust risk priority number (RPN) in FMEA.

Research limitations/implications

As manufacturing departments are mostly dealing with failure effects and modes of machinery and maintenance departments are mostly dealing with causes of failures, the proposed model can support better coordination and integration between the two departments. Such support seems to be more important in firms with continuous production lines wherein line interruption influences response to customers more seriously. A wide range of future study opportunities indicates the attractiveness and contribution of the subject to the knowledge of FMEA.

Originality/value

Although the literature indicates that in most of studies the outcomes of QFD were entered into FMEA and in some studies the RPN of FMEA was entered into QFD as importance rating, the proposed approach is a true type of the so-called “integration of FMEA and QFD” because the three main elements of FMEA formed the structure of QFD. In other words, the proposed approach can be considered as an innovation in the FMEA structure, not as a data provider prior to it or a data receiver after it.

Details

International Journal of Quality & Reliability Management, vol. 36 no. 8
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 23 August 2021

Fatemeh Shaker, Arash Shahin and Saeed Jahanyan

This paper aims to develop a system dynamics (SD) model to identify causal relationships among the elements of failure modes and effects analysis (FMEA), i.e. failure modes

Abstract

Purpose

This paper aims to develop a system dynamics (SD) model to identify causal relationships among the elements of failure modes and effects analysis (FMEA), i.e. failure modes, effects and causes.

Design/methodology/approach

A causal loop diagram (CLD) has been developed based on the results obtained from interdependencies and correlations analysis among the FMEA elements through applying the integrated approach of FMEA-quality function deployment (QFD) developed by Shaker et al. (2019). The proposed model was examined in a steel manufacturing company to identify and model the causes and effects relationships among failure modes, effects and causes of a roller-transmission system.

Findings

Findings indicated interactions among the most significant failure modes, effects and causes. Moreover, corrective actions defined to eliminate or relieve critical failure causes. Consequently, production costs decreased, and the production rate increased due to eliminated/decreased failure modes.

Practical implications

The application of CLD illustrates causal relationships among FMEA elements in a more effective way and results in a more precise recognition of the root causes of the potential failure modes and their easy elimination/decrease. Therefore, applying the proposed approach leads to a better analysis of the interactions among FMEA elements, decreased system's failure rate and increased system availability.

Originality/value

The literature review indicated a few studies on the application of SD methodology in the maintenance area, and no study was performed on the causal interactions among FMEA elements through an FMEA-QFD based SD approach. Although the interactions of these elements are significant and helpful in risks ranking, researchers fail to investigate them sufficiently.

Details

International Journal of Quality & Reliability Management, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 23 March 2010

Pao‐Tiao Chuang

To ensure the service quality, it is very important and necessary for a company to systematically identify and prioritize the critical failure modes that result in…

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1948

Abstract

Purpose

To ensure the service quality, it is very important and necessary for a company to systematically identify and prioritize the critical failure modes that result in disservice of quality, and take the required remedial actions before the service is delivered to customers. The purpose of this paper is to propose an approach to enhance perceived service quality by incorporating disservice analysis with failure modes and effects analysis (FMEA).

Design/methodology/approach

The approach, first, identifies the potential failure modes that might have explicit effects on the service quality. Subsequently, the risk priority number (RPN) is computed to identify the risk priority for each potential failure mode. Furthermore, a disservice index that represents the extent of composite adverse effect of service failures on quality perceptions is computed to recognize the disservice priority for each quality dimension. Based on which, vital quality dimensions are determined as those quality dimensions that have higher disservice indices. The critical failure modes are, then, confirmed as those failure modes that have higher RPNs in the vital quality dimensions. Finally, the effects and root‐causes of the critical failure modes are determined by thoroughly exploiting the service infrastructure, service design, and service encounter for the company to take effective remedial actions to enhance perceived service quality. A practical case regarding a hypermarket service was used to demonstrate the proposed approach. Managerial implications and suggestions are provided to the case company, the hypermarket industry, and other service industries. Possibilities for future research are also addressed.

Findings

The vital quality dimensions are determined as responsiveness and reliability for the hypermarket case. Six critical failure modes are confirmed, by the order of criticality, as “unstable supply of goods/merchandise,” “no goods/merchandise on designated shelf of the sales floor,” “slowness of cashier speed,” “tardiness of warranty/repair goods/merchandise,” “nonconforming quality of goods/merchandise,” and “unable to find first‐line server in the sales floor.” These critical failure modes should be eliminated or reduced in top priority to enhance perceived service quality. Note that the determination of vital quality dimensions and the confirmation of critical failure modes depend on the applicable company resources.

Originality/value

The proposed approach improves both the academic and the practical developments of service quality in five aspects: explicitly identifying potential mistakes or failures of the service system that might result in disservice of quality. Arousing notices and focuses on those failure modes that have higher risk priorities by performing FMEA. Identifying how seriously the service failures adversely affect each of the quality dimensions and determining what the vital quality dimensions are by carrying out disservice analysis. Confirming the critical failure modes as those failure modes that have higher risk priorities in the vital quality dimensions with higher disservice indices. Knowing what actions need to be taken in advance to enhance perceived service quality by identifying the root‐causes that result in those critical failure modes.

Details

Industrial Management & Data Systems, vol. 110 no. 3
Type: Research Article
ISSN: 0263-5577

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Article
Publication date: 28 June 2011

Vinay Sharma, Minakshi Kumari and Santosh Kumar

The purpose of this analysis was to attempt to improve the reliability of a rotor support system of a modern aircraft engine.

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1174

Abstract

Purpose

The purpose of this analysis was to attempt to improve the reliability of a rotor support system of a modern aircraft engine.

Design/methodology/approach

The process used for carrying out FMEA is specified by MIL‐STD‐1629A procedure for carrying out failure mode, effects and criticality analysis.

Findings

In increasing demand in the avionics sector, particularly in modern defence and civil aircraft, safety and reliability are the prime concerns to complete the mission successfully. Technocrats are made to rethink the safety of complete systems by adding redundancy to the critical activities. A rotor support system (RSS) is an integral part of a gas turbine engine used in any aircraft. As its name implies, the rotor support system shares the load of the rotating component of an engine, hence the rotor support system plays a vital role in any aircraft engine. It shares the load of compressor rotor and stator, turbine rotor and stator, inter‐casing, and exhaust system of a gas turbine engine. Any failure in such a system may make the entire aircraft fail. Therefore it is worth carrying out Failure Modes and Effects Analysis (FMEA) on such a critical system. FMEA is one of the effective reliability assessment tools, which evaluate systematically and document the potential failure modes of a system or equipment and their causes. It helps in grading the severity of all potential failure modes and is useful in carrying out the changes in the early phase of design. The analysis starts with the potential failure of the smallest component at the final indenture and goes up to the initial indenture level.

Originality/value

The paper adds insight into the reliability improvement of the rotor support system of modern aircraft.

Details

International Journal of Quality & Reliability Management, vol. 28 no. 6
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 16 October 2007

Chensong Dong

This paper aims to provide a cost effective failure mode and effects analysis tool to overcome the disadvantages of the traditional FMEA that the cost due to failure is…

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1223

Abstract

Purpose

This paper aims to provide a cost effective failure mode and effects analysis tool to overcome the disadvantages of the traditional FMEA that the cost due to failure is not defined.

Design/methodology/approach

The method presented in this paper is based on the fuzzy utility theory. It uses utility theory and fuzzy membership functions for the assessment of severity, occurrence, and detection. The utility theory accounts for the nonlinear relationship between the cost due to failure and the ordinal ranking. The application of fuzzy membership functions better represents the team opinions. The Risk Priority Index (RPI) is developed for the prioritization of failure modes.

Findings

The advantages of the FUT‐based FMEA are demonstrated through cases studies. It shows that it can take the cost due to failure into account when prioritizing failure modes.

Originality/value

The FUT‐based FMEA presented in this paper provides a convenient cost‐effective tool for failure analysis. It improves the performance FMEA in the risk and failure analysis for product design and manufacturing/assembly process.

Details

International Journal of Quality & Reliability Management, vol. 24 no. 9
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 1 February 2005

E.P. Zafiropoulos and E.N. Dialynas

The paper presents an efficient methodology that was developed for the reliability prediction and the failure mode effects and criticality analysis (FMECA) of electronic…

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3568

Abstract

Purpose

The paper presents an efficient methodology that was developed for the reliability prediction and the failure mode effects and criticality analysis (FMECA) of electronic devices using fuzzy logic.

Design/methodology/approach

The reliability prediction is based on the general features and characteristics of the MIL‐HDBK‐217FN2 technical document and a derating plan for the system design is developed in order to maintain low components’ failure rates. These failure rates are used in the FMECA, which uses fuzzy sets to represent the respective parameters. A fuzzy failure mode risk index is introduced that gives priority to the criticality of the components for the system operation, while a knowledge base is developed to identify the rules governing the fuzzy inputs and output. The fuzzy inference module is Mamdani type and uses the min‐max implication‐aggregation.

Findings

A typical power electronic device such as a switched mode power supply was analyzed and the appropriate reliability indices were estimated using the stress factors of the derating plan. The fuzzy failure mode risk indices were calculated and compared with the respective indices calculated by the conventional FMECA.

Research limitations/implications

Further research efforts are needed for the application of fuzzy modeling techniques in the area of reliability assessment of electronic devices. These research efforts can be concentrated in certain applications that have practical value.

Practical implications

Practical applications can use a fuzzy FMECA modeling instead of the classical FMECA one, in order to obtain a more accurate analysis.

Originality/value

Fuzzy modeling of FMECA is described which can calculate fuzzy failure mode risk indices.

Details

International Journal of Quality & Reliability Management, vol. 22 no. 2
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 3 August 2015

Hu-Chen Liu, Jian-Xin You, Xue-Feng Ding and Qiang Su

– The purpose of this paper is to develop a new failure mode and effect analysis (FMEA) framework for evaluation, prioritization and improvement of failure modes.

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1579

Abstract

Purpose

The purpose of this paper is to develop a new failure mode and effect analysis (FMEA) framework for evaluation, prioritization and improvement of failure modes.

Design/methodology/approach

A hybrid multiple criteria decision-making method combining VIKOR, decision-making trial and evaluation laboratory (DEMATEL) and analytic hierarchy process (AHP) is used to rank the risk of the failure modes identified in FMEA. The modified VIKOR method is employed to determine the effects of failure modes on together. Then the DEMATEL technique is used to construct the influential relation map among the failure modes and causes of failures. Finally, the AHP approach based on the DEMATEL is utilized to obtain the influential weights and give the prioritization levels for the failure modes.

Findings

A case study of diesel engine’s turbocharger system is provided to illustrate the potential application and benefits of the proposed FMEA approach. Results show that the new risk priority model can be effective in helping analysts find the high risky failure modes and create suitable maintenance strategies.

Practical implications

The proposed FMEA can overcome the shortcomings and improve the effectiveness of the traditional FMEA. Particularly, the dependence and interactions between different failure modes and effects have been addressed by the new failure analysis method.

Originality/value

This paper presents a systemic analytical model for FMEA. It is able to capture the complex interrelationships among various failure modes and effects and provide guidance to analysts by setting the suitable maintenance strategies to improve the safety and reliability of complex systems.

Details

International Journal of Quality & Reliability Management, vol. 32 no. 7
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 13 November 2007

Philip Lawrence and Simon Gill

This paper sets out to outline a human hazard analysis methodology as a tool for managing human error in aircraft maintenance, operations and production. The methodology…

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1606

Abstract

Purpose

This paper sets out to outline a human hazard analysis methodology as a tool for managing human error in aircraft maintenance, operations and production. The methodology developed has been used in a slightly modified form on Airbus aircraft programmes. This paper aims to outline a method for managing human error in the field of aircraft design, maintenance and operations. Undertaking the research was motivated by the fact that aviation incidents and accidents still show a high percentage of human‐factors events as key causal factors.

Design/methodology/approach

The methodology adopted takes traditional aspects of the aircraft design system safety process, particularly fault tree analysis, and couples them with a structured tabular notation called a human error modes and effects analysis (HEMEA). HEMEA provides data, obtained from domain knowledge, in‐service experience and known error modes, about likely human‐factors events that could cause critical failure modes identified in the fault tree analysis. In essence the fault tree identifies the failure modes, while the HEMEA shows what kind of human‐factors events could trigger the relevant failure.

Findings

The authors found that the methodology works very effectively, but that it is very dependent on locating the relevant expert judgement and domain knowledge..

Research limitations/implications

The authors found that the methodology works very effectively, but that it is very dependent on locating the relevant expert judgement and domain knowledge. Using the method as a prototype, looking at aspects of a large aircraft fuel system, was very time‐consuming and the industry partner was concerned about the resource implications of implementing this process. Regarding future work, the researchers would like to explore how a knowledge management exercise might capture some of the domain knowledge to reduce the requirement for discursive, seminar‐type sessions with domain experts.

Practical implications

It was very clear that the sponsors and research partners in the aircraft industry were keen to use this method as part of the safety process. Airbus has used a modified form of the process on at least two programmes.

Originality/value

The authors are aware that the UK MOD uses fault tree analysis that includes human‐factors events. However, the researchers believe that the creation of the human error modes effects analysis is original. On the civil side of the aviation business this is the first time that human error issues have been included for systems other than the flightdeck. The research was clearly of major value to the UK Civil Aviation Authority and Airbus, who were the original sponsors.

Details

Disaster Prevention and Management: An International Journal, vol. 16 no. 5
Type: Research Article
ISSN: 0965-3562

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Article
Publication date: 24 April 2007

M. Braglia, G. Fantoni and M. Frosolini

The purpose of this paper is to provide a structured methodology for performing build‐in reliability (BIR) investigation during a new product development cycle.

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2564

Abstract

Purpose

The purpose of this paper is to provide a structured methodology for performing build‐in reliability (BIR) investigation during a new product development cycle.

Design/methodology/approach

The methodology in this paper represents an extension of the Quality Functional Deployment/House of Quality (QFD/HoQ) concepts to reliability studies. It is able to translate the reliability requisites of customers into functional requirements for the product in a structured manner based on a Failure Mode And Effect Analysis (FMEA). Besides, it then allows it to build a completely new operative tool, named House of Reliability (HoR), that enhances standard analyses, introducing the most significant correlations among failure modes. Using the results from HoR, a cost‐worth analysis can be easily performed, making it possible to analyse and to evaluate the economical consequences of a failure.

Findings

The paper finds that the application of the proposed approach allows users to identify and control the design requisites affecting reliability. The methodology enhances the reliability analysis introducing and managing the correlations among failure modes, splitting the severity into a detailed series of basic severity aspects, performing also cost/worth assessments.

Practical implications

It is shown that the methodology enables users to finely analyse failure modes by splitting severity according to the product typology and the importance of each Severity criterion according to laws or international standards. Moreover the methodology is able to consider the “domino effectsand so to estimate the impact of the correlation between the causes of failure. Finally a cost/worth analysis evaluates the economical consequences of a failure with respect to the incurred costs to improve the final reliability level of the product.

Originality/value

The paper proposes a completely new approach, robust, structured and useful in practice, for reliability analysis. The methodology, within an integrated approach, overcomes some of the largely known limits of standard FMECA: it takes into account multiple criteria, differently weighted, it analyses the product considering not only the direct consequence of a failure, but also the reaction chain originated by a starting failure.

Details

International Journal of Quality & Reliability Management, vol. 24 no. 4
Type: Research Article
ISSN: 0265-671X

Keywords

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