Enhancing the failure mode and effect analysis methodology with fuzzy inference techniques

Traditional Failure Mode and Effect Analysis (FMEA) adopts the Risk Priority Number (RPN) ranking model to evaluate failure risks, to rank failures, as well as to prioritize actions. Although this approach is simple, it suffers from several shortcomings. In this paper, we investigate a number of fuzzy inference techniques for determining the RPN scores, in an attempt to overcome the weaknesses associated with the traditional RPN model. The main objective is to examine the possibility of using fuzzy rule interpolation and reduction techniques to design new fuzzy RPN models. The performance of the fuzzy RPN models is evaluated using a real-world case study pertaining to the test handler process in a semiconductor manufacturing plant. The FMEA procedure for the test handler is performed, and a fuzzy RPN model is developed. In addition, improvement to the fuzzy RPN model is proposed by refining the weights of the fuzzy production rules, hence a new weighted fuzzy RPN model. The ability of the weighted fuzzy RPN model in failure risk evaluation with a reduced rule base is also demonstrated.

A new application of an evolving tree to failure mode and effect analysis methodology

Failure Mode and Effect Analysis (FMEA) is a popular safety and reliability analysis methodology for examining potential failure modes of products, process, designs, or services, in a wide range of industries. Despite its popularity, there are a number of limitations of FMEA, and two highlighted issues are the bulky FMEA form and its intricacy of use. To overcome these shortcomings, we introduce the idea of visualisation pertaining to the failure modes or control actions in FMEA. A visualisation model with an incremental learning feature, i.e., the evolving tree (ETree), is adopted to allow the failure modes or control actions in FMEA to be clustered and visualized. The failure modes or control actions are grouped and visualized with consideration of their Severity, Occurrence, and Detection scores. Our proposed approach allows the failure modes or control actions to be mapped into a tree structure for visualisation. The devised approach is evaluated with a benchmark problem. The experiments show that the control actions of FMEA can be visualised through the tree structure, which provides a quick and easily understandable platform of the FMEA spreadsheet to facilitate decision making tasks.

A clustering-based failure mode and effect analysis model and its application to the edible bird nest industry

Failure mode and effect analysis (FMEA) is a popular safety and reliability analysis tool in examining potential failures of products, process, designs, or services, in a wide range of industries. While FMEA is a popular tool, the limitations of the traditional Risk Priority Number (RPN) model in FMEA have been highlighted in the literature. Even though many alternatives to the traditional RPN model have been proposed, there are not many investigations on the use of clustering techniques in FMEA. The main aim of this paper was to examine the use of a new Euclidean distance-based similarity measure and an incremental-learning clustering model, i.e., fuzzy adaptive resonance theory neural network, for similarity analysis and clustering of failure modes in FMEA; therefore, allowing the failure modes to be analyzed, visualized, and clustered. In this paper, the concept of a risk interval encompassing a group of failure modes is investigated. Besides that, a new approach to analyze risk ordering of different failure groups is introduced. These proposed methods are evaluated using a case study related to the edible bird nest industry in Sarawak, Malaysia. In short, the contributions of this paper are threefold: (1) a new Euclidean distance-based similarity measure, (2) a new risk interval measure for a group of failure modes, and (3) a new analysis of risk ordering of different failure groups. © 2014 The Natural Computing Applications Forum.

A new two-stage fuzzy inference system-based approach to prioritize failures in failure mode and effect analysis

This paper presents a new Fuzzy Inference System (FIS)-based Risk Priority Number (RPN) model for the prioritization of failures in Failure Mode and Effect Analysis (FMEA). In FMEA, the monotonicity property of the RPN scores is important. To maintain the monotonicity property of an FIS-based RPN model, a complete and monotonically-ordered fuzzy rule base is necessary. However, it is impractical to gather all (potentially a large number of) fuzzy rules from FMEA users. In this paper, we introduce a new two-stage approach to reduce the number of fuzzy rules that needs to be gathered, and to satisfy the monotonicity property. In stage-1, a Genetic Algorithm (GA) is used to search for a small set of fuzzy rules to be gathered from FMEA users. In stage-2, the remaining fuzzy rules are deduced approximately by a monotonicity-preserving similarity reasoning scheme. The monotonicity property is exploited as additional qualitative information for constructing the FIS-based RPN model. To assess the effectiveness of the proposed approach, a real case study with information collected from a semiconductor manufacturing plant is conducted. The outcomes indicate that the proposed approach is effective in developing an FIS-based RPN model with only a small set of fuzzy rules, which is able to satisfy the monotonicity property for prioritization of failures in FMEA.

A clustering-based failure mode and effect analysis model and its application to the edible bird nest industry

Failure mode and effect analysis (FMEA) is a popular safety and reliability analysis tool in examining potential failures of products, process, designs, or services, in a wide range of industries. While FMEA is a popular tool, the limitations of the traditional Risk Priority Number (RPN) model in FMEA have been highlighted in the literature. Even though many alternatives to the traditional RPN model have been proposed, there are not many investigations on the use of clustering techniques in FMEA. The main aim of this paper was to examine the use of a new Euclidean distance-based similarity measure and an incremental-learning clustering model, i.e., fuzzy adaptive resonance theory neural network, for similarity analysis and clustering of failure modes in FMEA; therefore, allowing the failure modes to be analyzed, visualized, and clustered. In this paper, the concept of a risk interval encompassing a group of failure modes is investigated. Besides that, a new approach to analyze risk ordering of different failure groups is introduced. These proposed methods are evaluated using a case study related to the edible bird nest industry in Sarawak, Malaysia. In short, the contributions of this paper are threefold: (1) a new Euclidean distance-based similarity measure, (2) a new risk interval measure for a group of failure modes, and (3) a new analysis of risk ordering of different failure groups.

A guided rule reduction system for prioritization of failures in fuzzy FMEA

Traditional Failure Mode and Effect Analysis (FMEA) utilizes the Risk Priority Number (RPN) ranking system to evaluate the risk level of failures, to rank failures, and to prioritize actions. Although this method is simple, it suffers from several shortcomings. In this paper, use of fuzzy inference techniques for RPN determination in an attempt to overcome the weaknesses associated with the traditional RPN ranking system is investigated. However, the fuzzy RPN model, suffers from the combinatorial rule explosion problem. As a result, a generic rule reduction approach, i.e. the Guided Rule Reduction System (GRRS), is proposed to reduce the number of rules that need to be provided by users during the fuzzy RPN modeling process. The proposed approach is evaluated using real-world case studies pertaining to semiconductor manufacturing. The results are analyzed, and implications of the proposed approach are discussed.

A non-linear programming-based similarity reasoning scheme for modelling of monotonicity-preserving multi-input fuzzy inference systems

In this paper, the zero-order Sugeno Fuzzy Inference System (FIS) that preserves the monotonicity property is studied. The sufficient conditions for the zero-order Sugeno FIS model to satisfy the monotonicity property are exploited as a set of useful governing equations to facilitate the FIS modelling process. The sufficient conditions suggest a fuzzy partition (at the rule antecedent part) and a monotonically-ordered rule base (at the rule consequent part) that can preserve the monotonicity property. The investigation focuses on the use of two Similarity Reasoning (SR)-based methods, i.e., Analogical Reasoning (AR) and Fuzzy Rule Interpolation (FRI), to deduce each conclusion separately. It is shown that AR and FRI may not be a direct solution to modelling of a multi-input FIS model that fulfils the monotonicity property, owing to the difficulty in getting a set of monotonically-ordered conclusions. As such, a Non-Linear Programming (NLP)-based SR scheme for constructing a monotonicity-preserving multi-input FIS model is proposed. In the proposed scheme, AR or FRI is first used to predict the rule conclusion of each observation. Then, a search algorithm is adopted to look for a set of consequents with minimized root means square errors as compared with the predicted conclusions. A constraint imposed by the sufficient conditions is also included in the search process. Applicability of the proposed scheme to undertaking fuzzy Failure Mode and Effect Analysis (FMEA) tasks is demonstrated. The results indicate that the proposed NLP-based SR scheme is useful for preserving the monotonicity property for building a multi-input FIS model with an incomplete rule base.

Optimization of gaussian fuzzy membership functions and evaluation of the monotonicity property of fuzzy inference systems

In this paper, two issues relating to modeling of a monotonicity-preserving Fuzzy Inference System (FIS) are examined. The first is on designing or tuning of Gaussian Membership Functions (MFs) for a monotonic FIS. Designing Gaussian MFs for an FIS is difficult because of its spreading and curvature characteristics. In this study, the sufficient conditions are exploited, and the procedure of designing Gaussian MFs is formulated as a constrained optimization problem. The second issue is on the testing procedure for a monotonic FIS. As such, a testing procedure for a monotonic FIS model is proposed. Applicability of the proposed approach is demonstrated with a real world industrial application, i.e., Failure Mode and Effect Analysis. The results obtained are analysis and discussed. The outcomes show that the proposed approach is useful in designing a monotonicity-preserving FIS model.

Fuzzy FMEA with a guided rules reduction system for prioritization of failures

Purpose – To propose a generic method to simplify the fuzzy logic-based failure mode and effect analysis (FMEA) methodology by reducing the number of rules that needs to be provided by FMEA users for the fuzzy risk priority number (RPN) modeling process.

Design/methodology/approach – The fuzzy RPN approach typically requires a large number of rules, and it is a tedious task to obtain a full set of rules. The larger the number of rules provided by the users, the better the prediction accuracy of the fuzzy RPN model. As the number of rules required increases, ease of use of the model decreases since the users have to provide a lot of information/rules for the modeling process. A guided rules reduction system (GRRS) is thus proposed to regulate the number of rules required during the fuzzy RPN modeling process. The effectiveness of the proposed GRRS is investigated using three real-world case studies in a semiconductor manufacturing process.

Findings – In this paper, we argued that not all the rules are actually required in the fuzzy RPN model. Eliminating some of the rules does not necessarily lead to a significant change in the model output. However, some of the rules are vitally important and cannot be ignored. The proposed GRRS is able to provide guidelines to the users which rules are required and which can be eliminated. By employing the GRRS, the users do not need to provide all the rules, but only the important ones when constructing the fuzzy RPN model. The results obtained from the case studies demonstrate that the proposed GRRS is able to reduce the number of rules required and, at the same time, to maintain the ability of the Fuzzy RPN model to produce predictions that are in agreement with experts' knowledge in risk evaluation, ranking, and prioritization tasks.

Research limitations/implications – The proposed GRRS is limited to FMEA systems that utilize the fuzzy RPN model.

Practical implications – The proposed GRRS is able to simplify the fuzzy logic-based FMEA methodology and make it possible to be implemented in real environments.

Originality/value – The value of the current paper is on the proposal of a GRRS for rule reduction to enhance the practical use of the fuzzy RPN model in real environments.

On monotonic sufficient conditions of fuzzy inference systems and their applications

An important and difficult issue in designing a Fuzzy Inference System (FIS) is the specification of fuzzy sets and fuzzy rules. In this paper, two useful qualitative properties of the FIS model, i.e., the monotonicity and sub-additivity properties, are studied. The monotonic sufficient conditions of the FIS model with Gaussian membership functions are further analyzed. The aim is to incorporate the sufficient conditions into the FIS modeling process, which serves as a simple (which can be easily understood by domain users), easy-to-use (which can be easily applied to or can be a part of the FIS model), and yet reliable (which has a sound mathematical foundation) method to preserve the monotonicity property of the FIS model. Another aim of this paper is to demonstrate how these additional qualitative information can be exploited and extended to be part of the FIS designing procedure (i.e., for fuzzy sets and fuzzy rules design) via the sufficient conditions (which act as a set of useful governing equations for designing the FIS model). The proposed approach is able to avoid the "trial and error" procedure in obtaining a monotonic FIS model. To assess the applicability of the proposed approach, two practical problems are examined. The first is an FIS-based model for water level control, while the second is an FIS-based Risk Priority Number (RPN) model in Failure Mode and Effect Analysis (FMEA). To further illustrate the importance of the sufficient conditions as the governing equations, an analysis on the consequences of violating the sufficient conditions of the FIS-based RPN model is presented.

On the use of fuzzy inference techniques in assessment models : part II : industrial applications

In this paper, we study the applicability of the monotone output property and the output resolution property in fuzzy assessment models to two industrial Failure Mode and Effect Analysis (FMEA) problems. First, the effectiveness of the monotone output property in a single-input fuzzy assessment model is demonstrated with a proposed fuzzy occurrence model. Then, the usefulness of the two properties to a multi-input fuzzy assessment model, i.e., the Bowles fuzzy Risk Priority Number (RPN) model, is assessed. The experimental results indicate that both the fuzzy occurrence model and Bowles fuzzy RPN model are able to fulfill the monotone output property, with the derived conditions (in Part I) satisfied. In addition, the proposed rule refinement technique is able to improve the output resolution property of the Bowles fuzzy RPN model.

An evolutionary-based similarity reasoning scheme for monotonic multi-input fuzzy inference systems

In this paper, an Evolutionary-based Similarity Reasoning (ESR) scheme for preserving the monotonicity property of the multi-input Fuzzy Inference System (FIS) is proposed. Similarity reasoning (SR) is a useful solution for undertaking the incomplete rule base problem in FIS modeling. However, SR may not be a direct solution to designing monotonic multi-input FIS models, owing to the difficulty in getting a set of monotonically-ordered conclusions. The proposed ESR scheme, which is a synthesis of evolutionary computing, sufficient conditions, and SR, provides a useful solution to modeling and preserving the monotonicity property of multi-input FIS models. A case study on Failure Mode and Effect Analysis (FMEA) is used to demonstrate the effectiveness of the proposed ESR scheme in undertaking real world problems that require the monotonicity property of FIS models.

Application of fuzzy inference techniques to FMEA

In traditional Failure Mode and Effect Analysis (FMEA), the Risk Priority Number (RPN) ranking system is used to evaluate the risk level of failures, to rank failures, and to prioritize actions. This approach is simple but it suffers from several weaknesses. In an attempt to overcome the weaknesses associated with the traditional RPN ranking system, several fuzzy inference techniques for RPN determination are investigated in this paper. A generic Fuzzy RPN approach is described, and its performance is evaluated using a case study relating to a semiconductor manufacturing process. In addition, enhancements for the fuzzy RPN approach are proposed by refining the weights of the fuzzy production rules.

Modern enhancements in teaching design theories to mechanical engineering students

This paper describes the application of computer aided design (CAD) in teaching advanced design methodologies to fourth-year undergraduate students majoring in mechanical engineering. This involves modern enhancements in teaching strategies for subjects such as design-for-X (DFx) and failure mode effect analysis (FMEA) concepts, which are traditionally categorised as advanced design methodologies. The main subsets of DFx including design-for-assembly (DFA), design-for-disassembly (DFD), design-for-manufacturing (DFM), design-for-environment (DFE) and design-for-recyclability (DFR) were covered by studying various engineering and consumer products. The unit was designed as a combination of practical hands-on workshop-based classes along with a software-based evaluation of different products. In addition to CAD, finite element modelling techniques were utilised to enhance the students’ understanding of design faults and failures. The inquiry into teaching practice and design of this fourth-year unit was carried out during past two years and it revealed some interesting outcomes from our teaching practice in terms of students’ learning experiences. Finally, the paper discusses some critical factors in the context of teaching advanced design methodologies to the undergraduates in mechanical engineering and even manufacturing engineering.