A guided rule reduction system for prioritization of failures in fuzzy FMEA

Traditional Failure Mode and Effect Analysis (FMEA) utilizes the Risk Priority Number (RPN) ranking system to evaluate the risk level of failures, to rank failures, and to prioritize actions. Although this method is simple, it suffers from several shortcomings. In this paper, use of fuzzy inference techniques for RPN determination in an attempt to overcome the weaknesses associated with the traditional RPN ranking system is investigated. However, the fuzzy RPN model, suffers from the combinatorial rule explosion problem. As a result, a generic rule reduction approach, i.e. the Guided Rule Reduction System (GRRS), is proposed to reduce the number of rules that need to be provided by users during the fuzzy RPN modeling process. The proposed approach is evaluated using real-world case studies pertaining to semiconductor manufacturing. The results are analyzed, and implications of the proposed approach are discussed.