A new fuzzy approach to identify the critical risk factors in maintenance management

Maintenance is carried out to prevent the occurrence of events that lead to malfunction and interruption of the production process or the operation of the concerned equipment. One of the main approaches in maintenance is to identify the risk of equipment failure mode. Whereas by reducing the high risk of failure mode the reliability and availability of equipment enhanced and the cost of shutdown reduced, identifying the risk of failure is important. In this paper, a fuzzy hybrid approach, including failure mode and effective analysis (FMEA), decision-making trial and evaluation laboratory technique (DEMATEL), and analytic network process (ANP), is presented to select an appropriate maintenance policy through identifying the risk of failures. The authors aim to develop a risk-based method for selecting a proper maintenance strategy to have available and reliable tamping equipment in railway of Iran. Because of considering the same weight of risk factors, failure occurrence, failure severity, and failure detection ability in FMEA, the traditional FMEA method cannot correctly predict the system’s behavior. So, in this paper, the risk factors as fuzzy variables are proposed and evaluated using fuzzy linguistic terms and fuzzy ratings. In a case study, the present approach is utilized for evaluation and determination of the risk of failure modes for a railway company. At first, fuzzy FMEA is used to identify the main risk and sub-risk of failure modes. Second, fuzzy DEMATEL method is used in order to put forward the interrelationship among the main risks which are determined through fuzzy FMEA. Then, the weights of the sub-risks are calculated by fuzzy ANP approach on the basis of cause–effect relationships that are exposed through DEMATEL method. Finally, the weights of sub-risks are determined by multiplying the weights which have been obtained from fuzzy FMEA to the weights of ANP supermatrix. The weights of sub-risks were determined on the basis of these examined dependencies, and these weights were used for a tamping machine to determine maintenance policy. Finally, some strategies and suggestions have been drawn concerning the needs to reduce the risks and improve the equipment’s availability.

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