A model based on FMEA and Fuzzy TOPSIS for risk prioritization in industrial processes

Abstract

Abstract: FMEA is one of the most used methods to support risk analysis in business processes. Nonetheless, this method has some limitations, including the use of only three decision criteria, whose weights are not considered. With the objective of adding new features to FMEA, some studies combine it with multicriteria decision methods. This study proposes a model based on FMEA and Fuzzy TOPSIS to support risk prioritization in industrial production processes. A pilot application was performed to analyze and prioritize the risks of potential failures in a nodular iron melting and casting process. Based on the opinion of four company experts, potential failure modes were defined and assessed. The experts also chose the criteria and their respective weights. The pilot application results suggest that “fading time exceeded” and “chemical composition outside of the specified” should be treated with highest priority. The sensitivity analysis test results corroborate the relevance of these failures and demonstrate the effect of criteria weight variation. The proposed model is useful to support the formulation of actions plans focused on minimizing or eliminating priority failures. Other contributions from this study consist of: considering criteria weight; allowing the use of linguistic terms to express the decision makers’ judgments; considering the costs relating to the failures; and supporting group decisions.