Performance analysis of a complex process industrial unit utilizing intuitionistic fuzzy-based integrated framework

Purpose An integrated intuitionistic fuzzy (IF) modelling-based framework for examining the performance analysis of a packaging unit (PU) in three different stages has been proposed. Design/methodology/approach For the series and parallel configuration of PU, a mathematical model based on the intuitionistic fuzzy Lambda–Tau (IFLT) approach was developed in order to calculate various reliability parameters at various spreads. For determining membership and non-membership function-based reliability parameters for the top event, AND/OR gate transitions expression was employed. Findings For 15%–30% spread, unit’s availability for the membership function falls by 0.006442%, and it falls even more by 0.014907% with an increase in spread from 30% to 45%. In contrast, for 15%–30% spread, the availability of non-membership function-based systems reduces by 0.007491% and further diminishes. Risk analysis has presented applying an emerging approach called intuitionistic fuzzy failure mode and effect analysis (IFFMEA). For each of the stated failure causes, the output values of the intuitionistic fuzzy hybrid weighted Euclidean distance (IFHWED)-based IFFMEA have been tabulated. Failure causes like HP1, MT6, FB9, EL16, DR23, GR27, categorized under subsystems, namely hopper, motor, fluidized bed dryer, distributor, grader and bin, respectively, with corresponding IFFMEA output scores 1.0975, 1.0190, 0.8543, 1.0228, 0.9026, 1.0021, were the most critical one to contribute in the system’s failure. Research limitations/implications The limitation of the proposed framework lies in the fact that the results obtained for both reliability and risk aspects mainly depend on the correctness of raw data provided by the experts. Also, an approximate model of PU is obtained from plant experts to carry performance analysis, and hence more attention is required in constructing the model. Under IFLT, reliability parameters of PU have been calculated at various spreads to study and analyse the failure behaviour of the unit for both membership and non-membership function in the IFS of 0.6,0.8. For both membership- and non-membership-based results, availability of the considered system shows decreasing trend. To improve the performance of the considered system, risk assessment was carried using IFFMEA technique, ranking all the critical failure causes against IFHWED score value, on which more attention should be paid so as to avoid sudden failure of unit. Social implications The livelihood of millions of farmers and workers depends on sugar industries. So perpetual running of these industries is very important from this viewpoint. On the basis of findings of reliability parameters, the maintenance manager could frame a correct maintenance policy for long-run availability of the sugar mills. This long-run availability will generate revenue, which, in turn, will ensure the livelihood of the farmers. Originality/value Mathematical modelling of the considered unit has been done applying basic expressions of AND/OR gate. IFTOPSIS approach has been implemented for ranking result comparison obtained under IFFMEA approach. Eventually, sensitivity analysis was also presented to demonstrate the stability of ranking of failure causes of PU.