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Classification Scheme for Root Cause and Failure Modes and Effects Analysis (FMEA) of Passenger Vehicle Recalls

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  • Chi, Chia-Fen
  • Sigmund, Davin
  • Astardi, Martin Octavianus

Abstract

This study analysed 345 passenger vehicle recalls that were reported to the National Highway Traffic Safety Administration. The root cause analysis was applied to analyse each recall event in order to derive the cause of the recall, i.e., the defect type. Classification schemes were developed to organize the defective components and defect type into useful categories. The defect types were classified into manufacturing defects, design flaws, and mislabelling. Each of the above categories was expanded into smaller subcategories and items. Following the root cause analysis, the functional block diagram, and failure modes and effects analysis (FMEA) were applied to translate defective recall cases into FMEA tabular statements. Cramer's V and Phi coefficient analyses were applied to identify significant associations between defective components and defect types to prevent the future recurrence of recalls and improve vehicle quality. This study demonstrated that root cause and FMEA, based on an orthogonal classification scheme, can be applied to derive feasible solutions for reducing vehicle safety recalls, and such analysis can be generalized to other products or manufacturing processes.

Suggested Citation

  • Chi, Chia-Fen & Sigmund, Davin & Astardi, Martin Octavianus, 2020. "Classification Scheme for Root Cause and Failure Modes and Effects Analysis (FMEA) of Passenger Vehicle Recalls," Reliability Engineering and System Safety, Elsevier, vol. 200(C).
    • Handle: RePEc:eee:reensy:v:200:y:2020:i:c:s0951832019311123
    DOI: 10.1016/j.ress.2020.106929
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    References listed on IDEAS

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    1. Nicholas G. Rupp, 2004. "The Attributes of a Costly Recall: Evidence from the Automotive Industry," Review of Industrial Organization, Springer;The Industrial Organization Society, vol. 25(1), pages 21-44, August.
    2. Gandoman, Foad H. & Ahmadi, Abdollah & Bossche, Peter Van den & Van Mierlo, Joeri & Omar, Noshin & Nezhad, Ali Esmaeel & Mavalizadeh, Hani & Mayet, Clément, 2019. "Status and future perspectives of reliability assessment for electric vehicles," Reliability Engineering and System Safety, Elsevier, vol. 183(C), pages 1-16.
    3. Peeters, J.F.W. & Basten, R.J.I. & Tinga, T., 2018. "Improving failure analysis efficiency by combining FTA and FMEA in a recursive manner," Reliability Engineering and System Safety, Elsevier, vol. 172(C), pages 36-44.
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