A hybrid MCDM-based FMEA model for identification of critical failure modes in manufacturing

The effective identification of critical failure modes of individual equipment components or processes and the development of plans for improvement are crucial for the manufacturing industry. Recently, the failure modes and effects analysis (FMEA) approach based on multiple criteria decision making (MCDM) has been utilized effectively for the assessment of primary failure modes and risks. However, the ranking results of failure modes produced by different MCDM methods might be different. This study proposes an integrated risk assessment model where several techniques are combined to produce an FMEA model for the generation of comprehensive failure mode ranking. First, the anticipated costs and environmental protection indicators are included in the FMEA model to enhance the comprehensiveness of assessment. Then, an influential network relationship map of risk factors is obtained by using the decision-making trial and evaluation laboratory (DEMATEL) technique to assist in identifying the critical factors. Finally, the ranking of the failure modes is identified using the four integrated MCDM methods, based on the technique for order preference by similarity to ideal solution (TOPSIS) concept. In addition, data from a machine tool manufacturing company survey are applied to demonstrate the effectiveness and robustness of the proposed model.