Fault Interaction Analysis in Manufacturing Process With Extended FMEA Model by Using Cloud Model Theory and DEMATEL: A Novel Approach for Risk Assessment

ABSTRACT Failure mode and effect analysis (FMEA) is widely used in numerous manufacturing processes to identify and minimize various problems; nevertheless, its usefulness is dubious until it is more directly associated with the resolution of complex issues. In addition, the disruptions experienced in the production process are interrelated and cannot be considered independent of each other. It is, therefore, pertinent to determine not only the significance of the faults, but also the nature of faults. This research includes the use of cloud model theory and evaluation of decision‐making experiments and test models to cater to the needs of industry. The current research is offering three things. First, the issue of random and uncertain decisions is resolved by applying Cloud Model Theory. Second, in order to identify critical faults, the Decision‐Making Trial and Evaluation Laboratory (DEMATEL) has been extended to take cloud model theory into account. Third, a case study is provided to highlight the advantages and effectiveness of this integrated approach. This integrated approach ensures that managers are cognizant of major risks and vulnerable areas to take precautionary measures in advance. As a result, losses resulting from detrimental effects and their deep‐rooted causes are minimized, and production processes become efficient and effective.