A Systematic Literature Review of Failure Mode and Effect Analysis (FMEA) Implementation in Industries

Abstract

Failure mode and effects analysis (FMEA) is a risk assessment tool that mitigates potential failures in systems, processes, designs, or services and has been used in a wide range of industries. The conventional risk priority number (RPN) method has been criticized for having many shortcomings. Various risk priority models have been proposed in various literature to improve the performance of the FMEA itself. However, there has been no literature review on this topic. This study reviewed 50 FMEA papers published between 1998 and 2019 in international journals and categorized them according to various industry and industry output. The automotive and manufacturing industries dominated the implementation of FMEA. For the industry's production: goods and services, mostly dominated by interests in implementing FMEA in their industries. Hopefully, this finding will be useful for goods and services industries willing to implement FMEA, especially the services industry.

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IJIEM (Indonesian Journal of Industrial Engineering & Management) Vol 1 No 2 June 2020, 59-68
59
A Systematic Literature Review of Failure Mode and Effect Analysis
(FMEA) Implementation in Industries
Akhyar Zuniawan
*
Master of Industrial Engineering Program, Mercu Buana University, Jl. Meruya Selatan No. 1, Jakarta 11610, Indonesia
A
RTICLE
I
NFORMATION
A B S T R A C T
Article history:
Received: 12 June 2020
Revised: 25 June 2020
Accepted: 27 June 2020
Category:
Review paper
Failure mode and effects analysis (FMEA) is a risk
assessment tool that mitigates potential failures in systems,
processes, designs, or services and has been used in a wide
range of industries. The conventional risk priority number
(RPN) method has been criticized for having many
shortcomings. Various risk priority models have been
proposed in various literature to improve the performance of
the FMEA itself. However, there has been no literature
review on this topic. This study reviewed 50 FMEA papers
published between 1998 and 2019 in international journals
and categorized them according to various industry and
industry output. The automotive and manufacturing
industries dominated the implementation of FMEA. For the
industry's production: goods and services, mostly dominated
by interests in implementing FMEA in their industries.
Hopefully, this finding will be useful for goods and services
industries willing to implement FMEA, especially the
services industry.
Keywords:
FMEA
RPN
Type of industries
Industries output
*Corresponding Author
Akhyar Zuniawan
E-mail: akhyar.zuniawan@gmail.com
This is an open access article under the CC–BY-SA license.
© 2020 Some rights reserved
1. INTRODUCTION
Failure mode and effects analysis (FMEA), first
developed as a formal design methodology in the
1960s by the aerospace industry, has proven to be
a useful and powerful tool in assessing potential
failures and preventing them from occurring.
FMEA is a technique to analyze, identify,
determine, and eliminate a known failure,
problem, or error with the potential of a system,
design, process, or service before they reach the
customer. The primary purpose of FMEA is to
identify potential failure modes, evaluate the
causes of failure and the effects of various
component failures. The analysis results can help
analysts identify and correct the failure modes that
have a detrimental effect on the system and
improve its performance during the stages of
design and production. And FMEA has been
widely used in various industries, including
aerospace, automotive, nuclear, electronics,
chemical, mechanical, food and beverage,
education, construction, medical technology, and
other industries. It is frequently observed that
productivity is related to guidelines for
productivity improvements achieved through
strategic planning (Gold, 1985). As a sector that
contributes to more than 50% of Gross Domestic
Product (GDP) in the global economy, the service
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IJIEM (Indonesian Journal of Industrial Engineering & Management) Vol 1 No 2 June 2020, 59-68
60
sector's importance will grow in the future (Gecky
et al., 2010). Currently, most FMEA is used for
industrial production that produces the goods, and
not much services industry using FMEA method.
2. LITERATURE REVIEW
FMEA is an important technique used to identify
and eliminate known failures or have the potential
to improve the reliability and security of complex
systems and is intended to provide critical
information for making decisions in risk
management. To analyze a specific product or
system, a cross-functional team should be
established for carrying out FMEA first. The first
step in FMEA is to identify all possible potential
failure modes of the product or system by a session
of systematic brainstorming. After that, critical
analysis is performed on these failure modes
taking into account the risk factors: occurrence
(O), severity (S), and detection (D). The purpose
of FMEA is to prioritize the failure modes of the
product or system to assign limited resources to
the most serious risk items. In general, the
prioritization of failure modes for corrective
actions is determined through the risk priority
number (RPN), which is obtained by finding the
multiplication of the O, S, and D of a failure. That
is: RPN = O x S x D. FMEA is a structured
technique that can help in identifying all failure
modes within a system, assessing their impact, and
planning for corrective actions, and to extend the
application of FMEA to risk management in the
construction industry (Abdelgawad & Fayek,
2010). In FMEA, component failures are linked to
risk events, while each failure can become the
object of detailed failure analysis and corrective
action planning (Aboutaleb et al., 2019). Due to
innovation in implementing and managing
projects, effective use of Failure Modes and
Effects Analysis (FMEA) technique has been
proposed (Bahrami et al., 2012). FMEA aims to
delight and satisfies the customer by preventing
failures that may occur at all levels from product
conception to its completion for delivery to ensure
improved quality and reliability of product
delivered in time for the user (Belu et al. 2013).
3. RESEARCH METHOD
This research aims to explore deeper into FMEA
implementation in various industries. The study
was carried out using the goals in mind. The terms'
FMEA' and 'Implementation in Industries' were
used to search for articles. The range of journals
published for this research from year 1998 to
2019.
This research was conducted by reviewing
80 papers found using FMEA. However, 30
journals did not meet the requirements and aspects
discussed. So it can be concluded that there are
only 50 journals left in accordance with this
discussion. So the data used in the journal is data
that has been implemented correctly in their
respective industries.
In this study, the author reviewed several
international journals, all of which were related to
the implementation of FMEA. The review in this
study is based on two aspects: (1) goods output;
(2) services output (Fig. 1).
Fig 1. Study framework
4. RESULT AND DISCUSSION
The 50 journals of FMEA implementation in
various industries were selected for review (Table
1). The selected journals or articles were analyzed
from the aspect of FMEA methodologies, consist
of FMEA basic concepts and FMEA
enhancement, then also analyzed by research
object and the result for following review of
selected articles.

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Table 1. Existing literature review of FMEA
No.
Literature Type of industries
Industries output
Result
1 Abdelgawad &
Fayek (2010)
Construction Goods
The result to obtain a value of RCN of 286. The RCA was
then used to calculate the RCN and the required corrective
actions for each risk event.
2 Aboutaleb et al.
(2012)
Project
Implementation
Services Some safety analyses are performed using FTA and
FMEA methods. But it represents just a small part of the
IS026262 functional safety.
3 Angara (2012) Oil and gas,
Biofuel
Goods From the charts, also the Pareto rule, the critical value for
RPN is 200 and for risk the score is 35.
4 Arvanitoyannis &
Varzakas (2009)
Food and
beverage
Goods The application for corrective action, the second
calculation of the RPN value that has been done, leads to
a much lower value compared to before the improvement
(< 130).
5 Arvanitoyannis &
Varzakas (2008)
Food and
beverage
Goods After applying corrective actions, the second calculation
of RPN values was carried out, resulting in substantially
lower values (below the acceptable upper limit of 130).
6 Azadeh et al.
(2009)
Oil and gas,
maintenance
Goods Based on the FMEA, faults (failure causes) are ranked and
prioritized and with regard to this analysis, the appropriate
preventive maintenance actions can be scheduled to
improve the RCM procedure and increase the overall
system reliability and help maintenance managers to
provide suitable preventive actions
7 Puvanasvaran &
Jamibollah (2014)
Automotive Goods The reject was decreasing from 4% become 0,9%.
8 Bahrami et al.
(2012)
Construction Goods Collapse one part of a total of excavation Vertical includes
with RPN (504, 810, 280, 324, 800, 216).
9 Baykasoğlu &
Gölcük (2017)
Manufacturing Goods The priorities of the FMs may differ considerably if the
causal dependencies are taken into consideration, and the
main advantage of the proposed model is that decision-
makers can better understand cause and effect
relationships among FMs and interpret the results.
10 Baynal at al.
(2018)
Automotive Goods The implementation of corrective and preventive activities
increases the doorstep assembly's 96 % improvement in
the door seal cuts problem.
11 Belu et al. (2013) Automotive Goods Thermo-forming requirements with the process function
of potential failure mode for missing material have the
biggest RPN with 240.
12
Bevilacqua et al.
(2015)
Medical,
healthcare
Services
Failure to register failure mode and lack of
transcription of
urgent drug deliveries performed have the highest RPN 80.
13 Kumar &
Parameshwaran
(2018)
Manufacturing Goods The transportation is reduced from 42 meters to 10 meters
approximately, hence reduces 76% of transportation
activity. The time involved in total transportation activity
also reduced from 2003 to 590 s; hence a saving of 70.5%
is obtained. The number of labours required is reduced
from 12 to 10.
14 Bluvband et al.
(2004)
Electronic,
communication
device
Goods Failed Product Due to Insufficient Strength for Change of
process temperature (RPN 72), Change of raw material
(RPN 45), Change of process pressure (RPN 29).
15 (Borković et al.
2017)
Media,
newspaper
Goods The production phase of time up to applying enough ink
reaches the RPN of 96, the RPN of the production phase
of time up to receive the first copy of the newspapers is
120, and the time of communication between foreman of
the rotation and dispatch revealed two cases non-
compliance is 100.
16 Braaksma et al.
(2013)
Manufacturing,
maintenance
Goods PAFMEA expresses a new perception in the evaluation
and prioritizes failure modes during failure analysis for
maintenance, such as risk definition and resource
availability, dealing with conflicting characteristics in a
decision-making approach.

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Table 1. Existing literature review of FMEA (continued)
No.
Literature Type of industries
Industries output
Result
17 Ignáczová (2016) Automotive,
warehouse
Goods Optimizing the storage space by 30% then brings
advantages in the workload of warehouse equipment by
7% and increases employees' productivity by 25%.
18 Ioannis et al.
(2013)
Oil and gas Goods Air compressor RPN increase from 90 to 270, Loss of
function, internal leakage of media RPN increase from 72
to 144, Air actuator fails to open or fails to close the valve
RPN increase from 36 to 108 fully.
19 Jahangoshai et al.
(2017)
Mining, stone
processing
Goods By using the FMEA method in the Parsian stone
processing industry company, there were 23 failures in the
company that was identified and weighed, and the
evaluation and priority of failures were carried out using
the RPN calculation.
20 Kangavari et al.
(2015)
Petrocemical Goods The RPN obtained to work at an altitude before taking
corrective action was 120 and decreased to 96 after
corrective action. Calculated RPN for all processes was
significantly reduced (p≤0.001) by implementing the
corrective actions.
21 Kania et al.
(2014)
Manufacturing,
tools
Goods Considering this problem on the basis of similarity to
quality management, one should introduce some
systematics: principles of eco-management, methods of
eco-management, tools of eco-management. The
methodology of EFMEA is a part of the scope of the eco-
management methods dedicated to the manufacturing
processes.
22 Khorshidi et al.
(2013)
Automotive, car
battery
Goods FMEA is not only used to select the high-risk processes
but also is employed as a process capability index to
evaluate the process chosen is still a key process or not.
23 Ku et al. (2008) Manufacture,
Maintenance
Goods From the simulated experiments of the proposed BPN-
based FMEA system (NFMEA), it has been found that the
accuracy of the failure modes classification and the
reliability calculation is knowledgeable and potential for
performing pragmatic preventive maintenance activities.
24 Kumar (2011) Manufacturing,
foundry
Goods The three main causes of waste accounted for 71.3 percent
of the accumulated WPN.
25 Kumar & Kumar
(2016)
Fertilizer Goods The FMEA method effectively and efficiently causes
AC7, CL3, ST2, DR3 and NR3 heat exchangers,
centrifugal compressors, ammonia reactors, ammonia
separators, and cold condenser reactors have been
identified as the most critical causes of failure of the
system under consideration.
26 Kumru & Kumru
(2013)
Medical Services With the implementation of all measures, it is expected to
decline about 20% in procurement time and 15% in time
spent by the workforce. Besides, the competition will
increase among suppliers, and the purchases will be made
more transparent.
27 Kurt & Ozilgen
(2013)
Food and
beverage
Goods To help a large number of dairy product manufacturers
produce safe products since the study provides
comprehensive real data collected from 75 audits carried
out in thirty dairy factories, and almost all dairy products
share a common manufacturing stage.
28 Kuzmanov et al.
(2017)
Manufacturing,
Steel
Goods Process for Transferring the done pieces into the
warehouse has a potential failure for a Damaged piece
(RPN 48), Long time for transfer (RPN 70), and Not
appropriate conditions into the warehouses (RPN 72).
29 Layzell &
Ledbetter (1998)
Construction,
cladding
Goods Investigates cladding failures on a system, component,
and process level and maps the cladding supply chain and
cladding related decision-making. The level of knowledge
of losses and the fragmented industry structure prevents
rigorous use of FMEA exemplified by other industries.
30
Lipol & Haq
(2011)
Manufacturing,
valve
Goods
RPN
-
Top 20% by Pareto and annoyance region [severity
are low, but occurrence ranking is high].

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Table 1. Existing literature review of FMEA (continued)
No.
Literature Type of industries
Industries output
Result
31 Mozaffari et al.
(2013)
Electronic, GEO
satellite
Services System complications can increase the initial increase of
79.15% rise to 97.52% for the specified life that can meet
the desired requirements.
32 Namdari et al.
(2011)
Agriculture Goods After implementing the results suggested by the FMEA,
fuel consumption decreased by 16.40%.
33 Nauman & Bano
(2014)
Medical,
pharmaceutical
Goods QRM increases awareness about risk and accelerates the
detection of a potential problem by analyzing and
comparing existing data from a quality perspective to
manage a product's quality, manufacturing process, and
compliance in a risk-based Quality Management System.
34 Özyazgan (2014) Textile Goods The company's critical failures are weft runs, warp runs,
basket, oil stain, slay, taras, leg failures, double weft and
weft pile, and it was determined that those failures are
caused by weaving machine and personnel.
35 Paciarotti et al.
(2014)
Manufacturing,
bathroom
equipment
Goods The revised FMEA allows to study the products' criticality
from a quality control point of view and organize specific
corrective actions to reduce the risk and improve the
efficiency and efficacy of quality control tasks.
36 Panchal et al.
(2018)
Fertilizer,
maintenance
Goods The causes CL4, CL6 with the same set of linguistic terms
(Very High, High, Fair) and (High, Medium, Medium)
produce different RPN score (216 and 189) and are ranked
differently. Still, fuzzy FMEA and GRA approach to
producing the same FRPN and grey output values (0.4819,
5.79 and 0.5523, 5.38), which entails that both these
causes are given the same priority.
37 Pantazopoulos &
Tsinopoulos
(2005)
Steel Goods The use of an FMEA can also be applied successfully in
various other business sectors (e.g., supplies, sales,
financial), leading to continual improvement and
increasing the bottom-line results.
38 Pareek (2012) Manufacturing,
foundry
Goods After implementing FMEA to the core manufacturing
process, core rejections and subsequent losses were
reduced to 4.2% of total rejections.
39
Su et al.
(
2010)
Automotive,
maintenance
Goods
The results show that the new risk priority model can
help
analysts find high-risk failure modes and create
appropriate maintenance strategies.
40 Popović et al.
(2010)
Maintenance,
Automotive
Goods Our efforts are new and, in our opinion, improved
approach to vehicle failure analysis, which gives a new
dimension to the entire process.
41 Ramli & ARffin
(2012)
Automotive Goods The RCM framework can only be produced when Class A
equipment is above the monthly maintenance frequency
priority, followed by Class B equipment and Class C
equipment, which has a lower critical value.
42 Rękas et al.
(
2014)
Manufacturing,
beverage can
Goods It results in low RPN for more than 85% of the failures
defined for a process of forming a can on a Bodymaker.
43 Renu et al. (2016) Automotive Goods The tool is used to identify and review quality issues
within a complete vehicle. The top ten issues identified
from the FMEA are submitted to design and
manufacturing engineers for detailed evaluations.
44 Parsana & Patel
(2014)
Manufacturing Goods For each specific process, the precautions suggested in the
table can reduce losses to the manufacturing industry both
in terms of time and cost.
45 Scipioni et al.
(2002)
Food and
beverage
Goods The FMEA and HACCP methodologies operated in
different production phases. Their simultaneous
application allowed them to study and analyze every
single step of production cycle and achieve exhaustive
knowledge and improvement of products and processes.
46 Selim et al.
(2016)
Food and
beverage
Goods Electrical and mechanical breakdowns decrease by about
15% and 53%, mean recovery times for the electrical and
mechanical breakdowns decrease by 32% and 21%.

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64
Table 1. Existing literature review of FMEA (continued)
No.
Literature Type of industries
Industries output
Result
47 Shahin &
Ravichandran
(2011)
Oil and gas Goods After taking corrective actions, the percentage of waste oil
is reduced from 1 to 0.08%, and the rate of canned
canisters has been reduced from initially 50,000 to 5,000
ppm
48 Sinthavalai &
Memongkol
(2008)
Education Services CRM is considered a wise solution that can be applied to
improve process efficiency and also to improve relations
with these organizations. Other failures were analyzed as
a result of the students' lack of preparation. As such, QFD
is a support tool for designing intensive courses for
student's practice.
49 Somsuk &
Pongpanich
(2008)
Electronic Goods By implementing FMEA, the defective parts could be
reduced from 6,294.36 DPPM to 3,788.27 DPPM.
50 Su et al. (2014) Electronic Goods The average failure time has increased from 1867 hours
to 4852 hours, and the development period has been
shortened to more than half a year.
4.1. Type of Industries
At the previous Table 1. Above, showing the most
dominant implementation FMEA mostly in the
manufacture and automotive industries. Of 50
papers collected in table 1, above mentioned 11
papers are discussions about the implementation
of FMEA in manufacturing industries, and ten
papers also talk about the implementation of
FMEA in automotive industries. The classification
articles based on the implementation of FMEA in
various industries can see in Fig.2 below.
Fig. 2. Implementation FMEA in various
industries.
The advantages of FMEA have resulted in its
implementation into nearly every branch of
modern industry, both for unitary and mass
production and the example of application of
FMEA in mass production is a production process
of beverage cans (Rękas et al. 2014). Failure mode
and effect analysis (FMEA) is methodologies that
facilitate process improvement and manufacturing
capabilities ( Puvanasvaran & Jamibollah 2014).
The classification based on percentage of
implementation FMEA in various industries we
can see at Fig.3 as below.
Fig. 3. Percentage implementation FMEA in
various industries.
From the fig.3 above, it is showing that the
percentage of comparison each industries in
implementing FMEA, founded the big 3 are
manufacture dominated 22% with the first rank,
next the second rank is by automotive industries
with 20% and the third is by food and beverage
with 5% of implementing FMEA. This
phenomenon indicated that most industries that
produce goods implementing FMEA to assess the
potential failure and improve, so the Severity,
Occurrence, Detection, and RPN will be reduced.
FMEA helps the SPC implementation either in
process selection or output analysis. Also, this
integration has been applied in a car battery
industry that is less-developed (Khorshidi et al.,
2013). FMEA method (Failure Modes and Effects
Analysis), which is widely used in the motor
vehicles industry (Popović et al. 2010).

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4.2 Year of Publication
The distribution of final samples per year of
publishing is shown in Figure 4. Some articles
published online that have been included in this
review can be seen from the following Fig. 4.
Fig. 4. Year of publication
From the data collected above, most researchers
publish the article for implementation FMEA in
the industry in year 2014, then followed in 2013.
This also indicated that in those years, the
researcher found some industrial problems that
have been solved using FMEA.
4.3 Industries Output
Fig. 5. is the result of a journal review that has
implemented FMEA of industries output. From 50
journals, showed 90% (around 45 journals) the
output produce is goods and the rest only 5%
showing the output produce is services.
Fig. 5. Goods and services output produce in
implementing FMEA
4.4 Research Challenge in Implementing of
FMEA in Industries produces output
For service industries, providing error-free
services is even more challenging because their
intangible nature renders subjective perceptions of
quality. Equally troublesome is the uncontrollable
element of customer participation in the service
process because production and consumption
occur as simultaneous processes. Despite these
challenges, however, service quality and customer
satisfaction are closely related constructs. When
service providers continuously strive to develop
error-free strategies, customer satisfaction is sure
to follow. And what potential rewards can FMEA
provide? Does the Service Company that will
conduct FMEA experience the following:
a. Minimized customer defection or increased
customer satisfaction?
b. Increased consistency in service quality?
c. Reduction of costly design changes?
d. Reduced transaction costs/increased profits?
e. Reduced reliability?
5. CONCLUSION
Although many endeavors have been dedicated to
utilizing FMEA in various industries sectors,
driven by the challenges in modern business and
the escalation of global disastrous events, the
implementation of FMEA in services sector gaps
is still left for future study. As this study is merely
based on limited literature, we encourage future
research to extend our initial survey using more
databases and incorporating other references such
as book chapters, dissertations, and literature.
Moreover, we also suggest that other researchers
to widen the discussion on the role of FMEA in
enhancing six sigma-oriented service systems and
its role in creating value within a collaborative
business framework.
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