Developing a 3D decision-making grid based on failure modes and effects analysis with a case study in the steel industry

Purpose: The aim of this study is to develop a 3D model of decision- making grid (DMG) considering failure detection rate. Design/methodology/approach: In a comparison between DMG and failure modes and effects analysis (FMEA), severity has been assumed as time to repair and occurrence as the frequency of failure. Detection rate has been added as the third dimension of DMG. Nine months data of 21 equipment of casting unit of Mobarakeh Steel Company (MSC) has been analyzed. Then, appropriate condition monitoring (CM) techniques and maintenance tactics have been suggested. While in 2D DMG, CM is used when downtime is high and frequency is low; its application has been developed for other maintenance tactics in a 3D DMG. Findings: Findings indicate that the results obtained from the developed DMG are different from conventional grid results, and it is more capable in suggesting maintenance tactics according to the operating conditions of equipment. Research limitations/implications: In failure detection, the influence of CM techniques is different. In this paper, CM techniques have been suggested based on their maximum influence on failure detection. Originality/value: In conventional DMG, failure detection rate is not included. The developed 3D DMG provides this advantage by considering a new axis of detection rate in addition to mean time to repair (MTTR) and failure frequency, and it enhances maintenance decision-making by simultaneous selection of suitable maintenance tactics and condition-monitoring techniques.