Abstract
FMEA analysis is a tool of quality improvement that has been widely used for decades. Its classical version prioritizes risk of failure by risk priority number (RPN). The RPN is a product of severity (S), occurrence (O), and detection (D), where all of the factors have equal levels of significance. This assumption is one of the most commonly criticized drawbacks, as it has given unreasonable results for real-world applications. The RPN can produce equal values for combinations of risk factors with different risk implications. Another issue is that of the uncertainties and subjectivities of information employed in FMEA analysis that may arise from lack of knowledge, experience, and employed linguistic terms. Many alternatives of risk assessment methods have been proposed to overcome the weaknesses of classical FMEA risk management in which we can distinguish methods of modification of RPN numbers of employing new tools. In this study, we propose a modification of the traditional RPN number. The main difference is that severity and occurrence are valued based on subfactors. The detection number remained unchanged. Additionally, the proposed method prioritizes risk in terms of implied risk to the systems by implementing functional failures (effects of potential failures). A typical fluid power system was used to illustrate the application of this method. The method showed the correct failure classification, which meets the industrial experience and other research results of failures of fluid power systems.