Fuzzy Based Failure Mode and Effect Analysis Towards to Risks of Autonomous Maintenance Activities: As a TPM Implementation
Manufacturing companies attach importance to Total Productive Maintenance (TPM) applications to extend equipment life and increase efficiency. The recommended applications with TPM are carried out under the pillar activities. Autonomous Maintenance (AM) pillar manage the assignments of the operators to undertake routine maintenance work on machine maintenance. Cleaning, lubrication and control activities are one of the steps of AM pillar and operators need to do them daily. However, there are a number of occupational health and safety risks that operators may face during these activities. Safety (S) pillar which serve as another TPM pillar, deal with occupational accidents and possible situations during TPM applications. AM and S pillars work together to assess the risks that may occur during AM applications. Failure Mode and Effect Analysis (FMEA) is also frequently utilized for risk assessment, but this is criticized in terms of the difficulty in reaching the common point of decision-makers’ risk assessment and equal weighting of risk factors. Therefore, it is appropriate to support with the fuzzy logic approach. In this study, the entropy-weighted fuzzy based FMEA method was utilized for identify and prioritize potential risks that may be encountered during the AM activities. Potential risks were revealed and evaluated with the FMEA team. Eleven potential risks were identified in the study. The risk factors of the assessment were weighted by the entropy method. The risk of hand injuring during cleaning the oil below material cutting saw has the highest risk priority.
___
- Alcan, P., Balin, A., & Başlıgil, H., (2013). Fuzzy Multicriteria
Selection among Cogeneration Systems: A Real Case
Application. Energy Build, 67: 624–634.
- Bao, J., Johansson, J., & Zhang, J. (2017). An Occupational
Disease assessment of the Mining Industry’s Occupational
Health and Safety Management System Based on FMEA
and an Improved AHP Model. Sustainability, 9(1), 94.
- Braglia, M. (2000). MAFMA: Multi-Attribute Failure Mode
Analysis. International Journal of Quality & Reliability Management,
17(9), 1017–1033.
- Braglia, M., Frosolini, M., & Montanari, R. (2003). Fuzzy TOPSIS Approach
For Failure Mode, Effects and Criticality Analysis. Quality
and Reliability Engineering International, 19(5), 425–443.
- Chang, C. L., Liu, P. H., & Wei, C. C. (2001). Failure Mode and Effects
Analysis Using Grey Theory. Integrated Manufacturing
Systems, 12(3), 211–216.
- Chang, C. L., Wei, C. C., & Lee, Y. H. (1999). Failure Mode and
Effects Analysis Using Fuzzy Method and Grey Theory.
Kybernetes, 28(9), 1072–1080.
- Chen, C. C. (2013). A Developed Autonomous Preventive Maintenance
Programme Using RCA and FMEA. International
Journal of Production Research, 51(18), 5404-5412.
- Chin, K. S., Wang, Y. M., Poon, G. K. K., & Yang, J. B. (2009). Failure
Mode and Effects Analysis by Data Envelopment Analysis.
Decision Support Systems, 48(1), 246–256.
- Chong, K. E., Ng, K. C., & Goh, G. G. G. (2015). Improving Overall
Equipment Effectiveness (OEE) through Integration of
Maintenance Failure Mode and Effect Analysis (maintenance-
FMEA) in a Semiconductor Manufacturer: A Case
Study. In 2015 IEEE International Conference on Industrial
Engineering and Engineering Management (IEEM) (1427-
1431). IEEE.
- Dağsuyu, C., Göçmen, E., Narlı, M., & Kokangül, A. (2016). Classical
and Fuzzy FMEA Risk Analysis In a Sterilization Unit.
Computers & Industrial Engineering, 101, 286-294.
- Eti, M. C., Ogaji, S. O. T., & Probert, S. D. (2004). Implementing
Total Productive Maintenance in Nigerian Manufacturing
Industries. Applied energy, 79(4), 385-401.
- Eti, M. C., Ogaji, S. O. T., & Probert, S. D. (2007). Integrating Reliability,
Availability, Maintainability and Supportability with
Risk Analysis for Improved Operation of the AFAM Thermal
Power-Station. Applied Energy, 84(2), 202-221.
- Garcia, P. A. A., Schirru, R., & Frutuoso Emelo, P. F. (2005). A Fuzzy
Data Envelopment Analysis Approach for FMEA. Progress
in Nuclear Energy, 46(3–4), 359.
- Hu, Y., Wu, S. & Cai, L. (2009). Fuzzy Multicriteria Decision
Making TOPSIS for Distribution Center Location
Selection. 2009 International Conference on Networks
Security, Wireless Communications and Trusted Computing
(Vol. 2, pp. 707-710). IEEE.
- Ilangkumaran, M., Shanmugam, P., Sakthivel, G., & Visagavel, K.
(2014). Failure Mode and Effect Analysis Using Fuzzy Analytic
Hierarchy Process. International Journal of Productivity
and Quality Management, 14(3), 296-313.
- Immawan, T., Sutrisno, W., & Rachman, A. K. (2018). Operational
Risk Analysis with Fuzzy FMEA (Failure Mode and Effect
Analysis) Approach (Case Study: Optimus Creative Bandung).
In MATEC Web of Conferences (Vol. 154, p. 01084). EDP
Sciences.
- Jamshidi, A., Rahimi, S. A., Ait-Kadi, D., & Ruiz, A. (2015). A Comprehensive
Fuzzy Risk-Based Maintenance Framework for
Prioritization of Medical Devices. Applied Soft Computing,
32, 322-334.
- Keay, E. & Borycki, E. (2010). Methods to Assess the Safety of
Health Information Systems. Healthcare Quarterly, 13(Special
issue), 47-52.
- Kutlu, A., C. & Ekmekçioğlu, M. (2012). Fuzzy Failure Modes and
Effect Analysis by Using Fuzzy TOPSIS-Based Fuzzy AHP.
Expert System with Applications, 39(1), 61-67.
- Liu, H. C. (2016). FMEA Using Uncertainty Theories and MCDM
Methods. In FMEA Using Uncertainty Theories and MCDM
Methods (13-27). Springer, Singapore.
- Liu, H. C., Liu, L., Liu, N., & Mao, L. X. (2012). Risk Evaluation in
Failure Mode and Effects Analysis with Extended VIKOR
Method under Fuzzy Environment. Expert Systems with
Applications, 39(17), 12926-12934.
- McKone, K. E., & Weiss, E. N. (1998). TPM: planned and Autonomous
Maintenance: Bridging the Gap between Practice
and Research. Production and operations management,
7(4), 335-351.
- Nakajima, S. (1988). Introduction to TPM. Productivity Press,
Cambridge, MA.
- Ostadi, B., & Saifpanahi, H. (2017). A Practical Self-Assessment
Framework for Evaluation of Maintenance Management
System based on RAMS Model and Maintenance Standards.
Journal of Industrial and Systems Engineering, 10,
125-143.
- Özveri, O., & Kabak, M. (2015). The Usage of MCDM Techniques
in Failure Mode and Effect Analysis. Journal of Economics
and Management Research, 4(2), p94-108.
- Pomorski, T. R. (2004). Total Productive Maintenance (TPM)
Concepts and Literature Review. Brooks Automation, 1-110.
Rodrigues, M., & Hatakeyama, K. (2006). Analysis of the Fall of
TPM in Companies. Journal of Materials Processing Technology,
179(1-3), 276-279.
- Salehi, M. & Tavakkoli-Moghaddam, R. (2008). Project
Selection by Using a Fuzzy TOPSIS Technique. World
Academy of Science, Engineering and Technology, 40,
85-90.
- Sanayei, A., Mousavi, S.F. & Yazdankhah, A. (2010). Group Decision
Making Process for Supplier Selection with VIKOR
under Fuzzy Environment. Expert Systems with Applications,
37(1), 24-30.
- Sarı, E. B. Toplam Verimli Bakım Uygulayan Bir İşletmede Bakım
Personelinin Performans Değerleme Puanlarının Entropi
Tabanlı VİKOR Sıralaması ile Karşılaştırılması. İşletme Bilimi
Dergisi, 5(3), 59-78.
- Selim, H., Yunusoğlu, M. G., & Yılmaz Balaman, Ş. (2016). A Dynamic
Maintenance Planning Framework Based on Fuzzy
TOPSIS and FMEA: Application in An International Food
Company. Quality and Reliability Engineering International,
32(3), 795-804.
- Shaikh, A., & Mettas, A. (2010). Application of Reliability,
Availability, and Maintainability Simulation to Process Industries:
A Case Study. In Simulation Methods for Reliability
and Availability of Complex Systems (173-197). Springer,
London.
- Shannon, C.E., & Weaver, W., (1947). A Mathematical Theory of
Communication, The University of Illinois Press, Urbana.
- Sharma RK, & Sharma P. (2010). System Failure Behavior and
Maintenance Decision Making Using, RCA, FMEA and
FM. Journal of Quality in Maintenance Engineering, 16 (1),
64 – 88.
- Sharma, R. K., Kumar, D., & Kumar, P. (2007). Modeling and
analysing system failure behaviour using RCA, FMEA and
NHPPP models. International Journal of Quality & Reliability
Management.
- Sharma, R. K., & Kumar, S. (2008). Performance Modeling Critical
Engineering Systems Using RAM Analysis. Reliability
Engineering & System Safety, 93(6), 913-919.
- Sharma, R. K., Kumar, D., & Kumar, P. (2005). Systematic Failure
Mode Effect Analysis (FMEA) Using Fuzzy Linguistic
Modelling. International Journal of Quality & Reliability
Management, 22(9), 986-1004.
- Sharma, R. K., Kumar, D., & Kumar, P. (2007). Modeling and
Analyzing System Failure Behaviour Using RCA, FMEA and
NHPPP Models. International Journal of Quality & Reliability
Management, 24(5), 525-546.
- Shirose, K. (1992). TPM for Operators. Portland, OR, Productivity
Press.
- Singh, R., Gohil, A. M., Shah, D. B., & Desai, S. (2013). Total Productive
Maintenance (TPM) Implementation in A Machine
Shop: A Case Study. Procedia Engineering, 51, 592-599.
- Souza RQ, & Álvares AJ. (2008). FMEA and FTA Analysis for Application
of Reliability-Centered Maintenance Methodology:
Case Study on Hydraulic Turbines. ABCM Symposium
Series in Mechatronics 2008, 3 :803 – 812.
- Stamatis, D. H. (2003). Failure Mode and Effect Analysis: FMEA
From Theory to Execution. ASQ Quality press.
- Tajiri, M., & Gotoh, F. (1992). TPM implementation, a Japanese
approach. New York, NY: McGraw-Hill.
- Tay, K. M., & Lim, C.P., (2006). Fuzzy FMEA with A Guided
Rules Reduction System for Prioritization of Failures. International
Journal Quality Reliability Management. 23(8),
1047–1066.
- Venkatesh, J. (2007). An Introduction to Total Productive Maintenance
(TPM). The Plant Maintenance Resource Center,
3-20.
- Wakjira, M. W., & Singh, A. P. (2012). Total Productive Maintenance:
A Case Study in Manufacturing Industry. Global
Journal of Research In Engineering, 12(1-G).
- Wang, Y.M., Chin, K.S., Poon, G.K.K., & Yang, J.B., (2009). Risk
Evaluation In Failure Mode and Effects Analysis Using
Fuzzy Weighted Geometric Mean. Expert Systems with
Applications, 36(2), 1195–1207.
- Yadav, O. P., Singh, N., Goel, P. S., & Itabashi-Campbell, R. (2003).
A Framework for Reliability Prediction during Product
Development Process Incorporating Engineering Judgements.
Quality Engineering, 15(4), 649-662.
- Zadeh, L.A. (1965). Fuzzy Sets. Information and Control, 8, 338-
383.
- Zadeh, L.A. (1975). The Concept of Linguistic Variable
and Its Application to Approximate Reasoning.
Information Sciences, 8, 199-249.
- Zeng, S. X., Tam, C. M., & Tam, V. W. (2010). Integrating Safety,
Environmental and Quality Risks for Project Management
Using a FMEA Method. Engineering Economics, 66(1), 44-
52.