Data-driven system reliability and failure behavior modeling using FMECA

Hadi Akbarzade Khorshidi, Indra Gunawan, Mahrous Ibrahim

Research output: Contribution to journalArticleResearchpeer-review

38 Citations (Scopus)


System reliability modeling needs a large amount of data to estimate the parameters. In addition, reliability estimation is associated with uncertainty. This paper aims to propose a new method to evaluate the failure behavior and reliability of a large system using failure modes, effects, and criticality analysis (FMECA). Therefore, qualitative data based on the judgment of experts are used when data are not sufficient. The subjective data of failure modes and causes have been aggregated through the system to develop an overall failure index (OFI). This index not only represents the system reliability behavior, but also prioritizes corrective actions based on improvements in system failure. In addition, two optimization models are presented to select optimal actions subject to budget constraint. The associated costs of each corrective action are considered in risk evaluation. Finally, a case study of a manufacturing line is introduced to verify the applicability of the proposed method in industrial environments. The proposed method is compared with conventional FMECA approach. It is shown that the proposed method has a better performance in risk assessment. A sensitivity analysis is provided on the budget amount and the results are discussed.

Original languageEnglish
Article number7104106
Pages (from-to)1253-1260
Number of pages8
JournalIEEE Transactions on Industrial Informatics
Issue number3
Publication statusPublished - 1 Jun 2016


  • Effects and criticality analysis
  • failure modes
  • genetic algorithm (GA)
  • overall failure index (OFI)
  • qualitative data
  • reliability modeling
  • uncertainty
  • universal generating function (UGF)

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