Failure mode and effects analysis: a novel approach applied in a parts manufacturing company

This study proposes a new method for performing failure mode and effects analysis called Amended Failure Mode and Effects Analysis (AFMEA) based on quantitative data rather than relying on expertise, and employs the cost of various failures in order to make more accurate and cost-oriented decisions for preventive maintenance actions. Considering different failure expenses, dependability of parameters, and replication of failure causes in the new method, we put forward new formulations for calculating three main components of risk priority number (RPN). Propounding a case study from an automotive supplier, we compare the results of the traditional FMEA with the new outcomes in order to gain some experience with the modified method and analyze its usefulness. The performance of AFMEA will then be discussed and evaluated with datasets in three different periods using receiver-operating characteristics (ROC) curves. The result shows the superiority of Amended FMEA in contrast with the traditional FMEA.

Keywords:

Failure Mode and Effects Analysis (FMEA) , Maintenance Management , Costs , ROC Analysis