Improved FMEA analysis method for electromechanical products based on FMAS decomposition

Conventional failure mode and effect analysis (FMEA) approaches applied to electromechanical products are typically derived from methodologies developed for electronic systems. These approaches are often characterized by cumbersome procedures that are time-consuming and susceptible to error. Additionally, the selected analysis objects in existing methods do not adequately capture the inherent characteristics of electromechanical systems, which are governed by the principle that motion defines function while structural support ensures motion feasibility. To address these limitations, this study adopts a “Function-Motion-Action/Support” (FMAS) framework for the structural decomposition of electromechanical product functions. Through this framework, fundamental meta-actions and the corresponding supporting elements that ensure proper motion execution are identified. Meta-actions are selected as the primary analysis objects. The SF-DEMATEL and SF-MABAC methods are subsequently integrated to distinguish between critical and less significant meta-actions. Failure modes, causes, and effects are then analyzed for the critical meta-actions. The proposed M-FMEA method is evaluated in terms of rationality, applicability, and simplicity, demonstrating clear advantages over traditional FMEA techniques. A case study involving a domestic CNC machine tool is conducted to validate the practicality and effectiveness of the FMAS decomposition and M-FMEA methodology.