An integrated Approach to Determine the Interrelationship among Faults in Production Process with Extended FMEA Model using DEMATEL and Cloud Model Theory

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.