Failure mode, effects and criticality analysis improvement by using new criticality assessment and prioritization based approach

Purpose This paper aims to enable the analysts of reliability and safety system to assess the criticality and prioritize failure modes perfectly to prefer actions for controlling the risks of undesirable scenarios. Design/methodology/approach To resolve the challenge of uncertainty and ambiguous related to the parameters, frequency, non-detection and severity considered in the traditional approach failure mode effect and criticality analysis (FMECA) for risk evaluation, the authors used fuzzy logic where these parameters are shown as members of a fuzzy set, which fuzzified by using appropriate membership functions. The adaptive neuro-fuzzy inference system process is suggested as a dynamic, intelligently chosen model to ameliorate and validate the results obtained by the fuzzy inference system and effectively predict the criticality evaluation of failure modes. A new hybrid model is proposed that combines the grey relational approach and fuzzy analytic hierarchy process to improve the exploitation of the FMECA conventional method. Findings This research project aims to reflect the real case study of the gas turbine system. Using this analysis allows evaluating the criticality effectively and provides an alternate prioritizing to that obtained by the conventional method. The obtained results show that the integration of two multi-criteria decision methods and incorporating their results enable to instill confidence in decision-makers regarding the criticality prioritizations of failure modes and the shortcoming concerning the lack of established rules of inference system which necessitate a lot of experience and shows the weightage or importance to the three parameters severity, detection and frequency, which are considered to have equal importance in the traditional method. Originality/value This paper is providing encouraging results regarding the risk evaluation and prioritizing failures mode and decision-makers guidance to refine the relevance of decision-making to reduce the probability of occurrence and the severity of the undesirable scenarios with handling different forms of ambiguity, uncertainty and divergent judgments of experts.