A New Approach for Failure Modes, Effects, and Criticality Analysis Using ExJ-PSI Model—A Case Study on Boiler System

Failure Modes, Effects, and Criticality Analysis are widely used to assess the failure modes of a system, along with their causes and effects. Several Multi-Criteria Decision-Making approaches have been developed to overcome the limitations of the traditional FMECA. In these approaches, several multiple criteria are considered to determine the criticality values and assign criticality ranks. In these developed approaches, only one expert can involve in criticality analysis. By incorporating several experts from design, manufacturing, and maintenance domains in the criticality analysis accuracy of the results can be improved. This paper proposes a new integrated Expert Judgment-based Preference Section Index (ExJ-PSI) model that combines MCDM approaches and integrates expert opinions. The proposed model is applied to a boiler system used in the textile industry. The results are compared with those obtained from the conventional FMECA and normalized median method. In the present study, the opinions of seven experts from various domains and organizations are discussed. To normalize the collected data, one scale is developed by considering four expert criteria, such as the experience of the expert, the number of boilers he is handling, the number of employees under his supervision, and the proficiency in the field. The proposed model is more effective and flexible in handling and analyzing data of complex configured systems consisting of many subsystems, components, and failure modes. The analysis reveals that the feed water pump, feed water pump motor, supply water temperature sensor, return water temperature sensor, header, and coal feed motor are some of the most critical components of the boiler system.