Improved FMEA Risk Assessment Based on Load Sharing and Its Application to a Magnetic Lifting System

Failure Mode and Effects Analysis (FMEA) is a systematic risk assessment tool that effectively evaluates the safety and reliability of products prior to their deployment. However, traditional FMEA fails to consider and leverage inherent system-specific information during risk assessment, while also neglecting the weights of risk factors (RFs) when processing data related to the Risk Priority Number (RPN). This leads to significant subjectivity in the final risk ranking of failure modes. To overcome these drawbacks, this study proposes an improved FMEA risk assessment method based on load sharing, aiming to develop an improved FMEA method that addresses the critical limitations of traditional approaches by integrating load sharing principles and systematic weight determination, thereby enhancing risk assessment objectivity and accuracy in complex multi-component systems. First, probabilistic linguistic terms are adopted to quantify experts’ risk assessment information, and the geometric mean method is then used to aggregate assessments from multiple experts. Second, the Fuzzy Best–Worst Method (FBWM) is employed to determine the relative weights of the three RPN factors (Occurrence, Severity, and Detection). Additionally, partial system structural data are obtained through load sharing, and these data—combined with the calculated factor weights—are integrated into the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) to generate the final risk ranking of failure modes. Finally, a case study of a magnetic crane is conducted to verify the feasibility and effectiveness of the proposed method, supplemented by comparative experiments to demonstrate its superiority.