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Multi-view FMEA Re-Validation: Efficient Risk and Engineering Knowledge Integration in Agile Production Systems Engineering

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Abstract

In agile Production Systems Engineering (PSE), multi-disciplinary teams work concurrently on various PSE artifacts in an iterative process that can be supported by common concept and Product-Process-Resource (PPR) modeling. However, keeping track of the interactions and effects of changes across engineering disciplines and their implications for risk assessment is exceedingly difficult in such settings. To tackle this challenge and systematically co-evolve Failure Mode and Effects Analysis (FMEA) and PPR models during PSE, it is necessary to propagate and validate changes across engineering artifacts. To this end, we design and evaluate a FMEA-linked-to-PPR assets (FMEA+PPR) meta model to represent relationships between FMEA elements and PSE assets and trace their change states and dependencies in the design and validation lifecycle. Furthermore, we design and evaluate the FMEA+PPR method to efficiently re-validate FMEA models upon changes in multi-view PSE models. We evaluate the model and method in a feasibility study on the quality of a joining process automated by a robot cell in automotive PSE. The study results indicate that the FMEA+PPR method is feasible and addresses requirements for FMEA re-validation better than alternative traditional approaches. Thereby, the FMEA+PPR approach facilitates a paradigm shift from traditional, isolated PSE and FMEA activities towards an integrated agile PSE method.

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... We use Design Science, extending our previous work [32], [33] by (i) conducting a domain analysis to identify requirements, (ii) designing and evaluating the MvFMEA+PPR metamodel to represent relationships between FMEA elements and PPR assets and (iii) providing a method to trace their change states and dependencies in the design and validation lifecycle. We evaluate the MvFMEA+PPR model and method in a feasibility study on the quality of a joining process. ...
... This section introduces the use case FMEA Re-Validation after Changes to Engineering Artifacts to elicit requirements for improving the efficiency of FMEA and PPR co-evolution. We report on PSE and FMEA re-validation processes abstracted from real-world use cases from system integrators of high-performance automation for car part manufacturing in Germany and Austria [33]. ...
... To address the requirements (cf. Section IV), we introduce the MvFMEA+PPR meta-model based on [33]. Specific concepts and relations for the initial MvFMEA+PPR meta-model have been partially derived from (a) an FMEA Ontology [36], (b) the VDI 3682 [4], and (c) the VDI 3682 Ontology-Design-Pattern [37]. ...
Conference Paper
In agile Cyber-physical Production System (CPPS) engineering, multi-disciplinary teams work concurrently and iteratively on various CPPS engineering artifacts, based on engineering models and Product-Process-Resource (PPR) knowledge, to design and build a production system. However, in such settings it is difficult to keep track of (i) the effects of changes across engineering disciplines, and (ii) their implications on risks to engineering quality, represented in Failure Mode and Effects Analysis (FMEA). To tackle these challenges and systematically co-evolve FMEA and PPR models, requires propagating and validating changes across engineering and FMEA artifacts. To this end, we design and evaluate a Multi-view FMEA+PPR (MvFMEA+PPR) meta-model to represent relationships between FMEA elements and CPPS engineering assets and trace their change states and dependencies in the design and validation lifecycle. We evaluate the MvFMEA+PPR meta-model in a feasibility study on the quality of a screwing process from automotive production. The study results indicate the MvFMEA+PPR meta-model to be more effective than alternative traditional approaches.
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