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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.

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

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.

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.

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.

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.

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.

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 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.

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.

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.

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.

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.

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.

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.

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.

Research carried out to develop and advance the application of design and process failure mode and effects analysis (FMEA) at Garrett Automotive Ltd, Skelmersdale, is described. The work has been undertaken under the umbrella of the UMIST Total Quality Management Multi‐company Teaching Programme. From an analysis of the present methods of preparing and using FMEAs, procedural changes have been made which have resulted in more effective use of the technique. The findings include the reluctance of product engineering and manufacturing engineering personnel to take a leading role in the preparation of design and process FMEAs, respectively. The main reasons for this relate to a perceived lack of time or lack of understanding of the technique′s potential. It is also pointed out that, in the past, FMEAs have mainly been used to satisfy the demands of major customers and it takes some considerable effort to ensure that FMEAs are prepared and used in the correct manner.

Discusses the implementation of failure mode and effects analysis (FMEA) for both product design and process control. FMEA is implemented in two ways to ensure that the reliability requirements are met for the production of an airbag inflator. Design FMEA is performed to generate a process control plan, visual aids, and a process verification list. Design FMEA and process FMEA are integrated through reliability prediction and supplier PPM reports. The supplier PPM reports contain the information that can be employed to update the probabilities used in design FMEA. The results of reliability predictions are fed back to eliminate the design weakness. Demonstrates the integrated procedure of the FMEA approach and discusses the relationships among useful tools.

The purpose of this paper is 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 failure mode and effects analysis (FMEA) approach for assessing the risks associated with GSC for benchmarking the performance in terms of effective GSC management adoption and sustainable production.

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 RPNs. A plastic manufacturer GSC case exemplar of the proposed model is illustrated to present the authenticity of this method of risk assessment.

Results indicate 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.

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.

This paper aims to enable the analysts of reliability and safety systems to evaluate the risk and prioritize failure modes ideally to prefer measures for reducing the risk of undesired events.

To address the constraints considered in the conventional failure mode and effects analysis (FMEA) method for criticality assessment, the authors propose a new hybrid model combining different multi-criteria decision-making (MCDM) methods. The analytical hierarchy process (AHP) is used to construct a criticality matrix and calculate the weights of different criteria based on five criticalities: personnel, equipment, time, cost and quality. In addition, a preference ranking organization method for enrichment evaluation (PROMETHEE) method is used to improve the prioritization of the failure modes. A comparative work in which the robust data envelopment analysis (RDEA)-FMEA approach was used to evaluate the validity and effectiveness of the suggested approach and simplify the comparative analysis.

This work aims to highlight the real case study of the automotive parts industry. Using this analysis enables assessing the risk efficiently and gives an alternative ranking to that acquired by the traditional FMEA method. The obtained findings offer that combining of two multi-criteria decision approaches and integrating their outcomes allow for instilling confidence in decision-makers concerning the risk assessment and the ranking of the different failure modes.

This research gives encouraging outcomes concerning the risk assessment and failure modes ranking in order to reduce the frequency of occurrence and gravity of the undesired events by handling different forms of uncertainty and divergent judgments of experts.

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.

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.

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.

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.

The purpose of this paper is to report a research in which fuzzy assessment of failure mode and effect analysis (FMEA) was examined on the design of rotary switches.

In the case study reported in this paper, fuzzy FMEA of a rotary switch was analysed, starting from its individual components to subsystems. Failure modes were identified and the effect of these modes was studied, then the results before and after taking actions were compared.

The usage of fuzzy FMEA enabled the reflection of real situation for determining the interdependencies among failure modes and effects of rotary switches with the incorporation of knowledge and expertise of experts.

The assessment has been attempted on a single rotary switch assembly. In future, this method can be applied in complex systems.

The paper shows that the method enabled the decision makers to share information from various working groups.

The case study has been conducted in a rotary switches manufacturing organisation and the results before and after improvement have been compared.