A model based on FMEA and Fuzzy TOPSIS for risk prioritization in industrial processes1

Wauires Ribeiro de Magalhães; Francisco Rodrigues  Lima Junior

doi:10.1590/1806-9649-2020v28e5535

Original Article

A model based on FMEA and Fuzzy TOPSIS for risk prioritization in industrial processes¹

Um modelo baseado em FMEA e Fuzzy TOPSIS para priorização de riscos em processos industriais

Wauires Ribeiro de Magalhães; Francisco Rodrigues Lima Junior

http://dx.doi.org/10.1590/1806-9649-2020v28e5535 Gest. Prod., vol.28, n4, e5535, 2021

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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.

Keywords

Risk assessment, FMEA, Fuzzy TOPSIS, Multicriteria decision-making

Resumo

Resumo:: O FMEA é um dos métodos mais utilizados para apoiar a análise de riscos em processos empresariais. Apesar disso, esse método apresenta algumas limitações, incluindo o uso de apenas três critérios de decisão, cujos pesos não são considerados. Com o objetivo de incrementar novos recursos ao FMEA, alguns estudos o combinam com métodos de decisão multicritério. Este estudo propõe um modelo baseado em FMEA e Fuzzy-TOPSIS para apoiar a priorização de riscos em processos de produção industrial. Uma aplicação piloto foi executada a fim de analisar e priorizar os riscos de falhas potenciais em um processo de fusão e vazamento de ferro nodular. Baseando-se na opinião de quatro especialistas da empresa, os modos de falhas potenciais foram definidos e avaliados. Os especialistas também escolheram os critérios e seus respectivos pesos. Os resultados da aplicação piloto sugerem que as falhas “tempo de fading excedido” e “composição química fora do especificado” sejam tratadas com maior prioridade. Os resultados dos testes de análise de sensibilidade ratificam a relevância destas falhas e evidenciam o efeito da variação dos pesos nos critérios. O modelo proposto é útil para apoiar a formulação de planos de ação focados na minimização ou eliminação das falhas prioritárias. Outras contribuições deste estudo consistem em: considerar os pesos dos critérios; permitir o uso de termos linguísticos para expressar os julgamentos dos decisores; considerar os custos referentes às falhas; e apoiar decisões em grupo.

Palavras-chave

Avaliação de riscos, FMEA, Fuzzy-TOPSIS, Tomada de Decisão multicritério

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