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April 15, 2026Applied SciencesOpen Access

Data-Driven Process FMEA for Flexible Manufacturing Systems: Framework and Industrial Case Study

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Authors

DKDobri KomarskiVVV. VassilevSNSG Nikolov

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Overview

Data-driven approach enhances risk analysis in flexible automated assembly lines, suggesting improved quality management practices.

Key Points

  • The research aims to integrate operational data with PFMEA to improve quality management in flexible automated assembly lines.
  • Developed a comprehensive data-driven framework combining classical quality tools and PFMEA.
  • Created structured data transformation pipeline linking operational logs to PFMEA ratings.
  • Applied the framework to analyze a modular FAAL for bearing units including various product configurations.
  • Identified 40 distinct failure modes with RPN values from 60 to 378.
  • Discovered that approximately 90% of the risk is linked to pneumatic systems.
  • Monte Carlo analysis showed top five failure modes consistently ranked in over 90% of simulations.

Cite This Study

Komarski et al. (2026) studied this question.

synapsesocial.com/papers/69df2c50e4eeef8a2a6b1563https://doi.org/10.3390/app16083760
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