Abstract:
Although Failure Mode and Effect Analysis (FMEA) is a common method for
identifying and mitigating potential problems in various manufacturing processes, its
usefulness can be enhanced if it is extended to cope with complex problems. Moreover,
it is also widely accepted that the faults plaguing manufacturing processes are
intertwined in such a way that they cannot be considered as independent of each other.
Instead, they have intermingling impacts and by not paying due heed to such
interrelationships, a research may tarnish the authenticity of its outcomes. Therefore, it
is pertinent to identify not only the prominence but also the nature of these faults. In
order to cater to such needs of industry and to overcome the limitations of traditional
methods, the proposed approach integrates the applications of cloud model theory and
DEMATEL method. The three contributions of this approach are: First, the cloud model
theory is applied to handle the problem of processing random and uncertain judgements.
The DEMATEL approach is expanded to take into account the cloud model setting in
order to allow for unveiling the crucial faults. Third, a case study is offered which
demonstrates the benefits and usefulness of the approach. The combination of Cloud
model theory and DEMATEL to expand traditional FMEA and to realize its
applicability in production processes underscore the novelty of this research. The
approach not only ranks the faults but also categorize them into cause and effect groups.
The findings show that among the faults, Turn Drum Jam in Max is the most vulnerable
one in terms of effect while Tobacco Rod Break in SE is the most prominent cause.
This is how this approach makes managers cognizant of the most vulnerable areas,
allowing them to come up with pre-emptive measure. Consequently, the manufacturing
process witnesses efficiency and effectiveness owing to significant reduction in the
losses it incurs due to interrelated faults.
