Abstract
With the aid of the Finite State Machine (FSM) and formal verification, a framework of updated Functional Resonance Analysis Method (FRAM) is proposed to refine operation guidelines as such and hence improves manufacturing processes by reducing risks of unqualified products during manufacturing operations. Firstly, the FRAM is used to model a manufacturing process in terms of the corresponding guideline, taking into account all the basic activities each with their performance variability and the potential couplings among the activities. Secondly, based on the FRAM model further interpreted with FSM, the model checker SPIN is adopted to achieve the exhaustive search (in the sense of execution) for the paths leading to manufacturing risks, which supports to illustrate how the performance variability in the activities couples and finally causes violation of quality control requirements. Finally, possible inadequacies and deficiencies of the operations are identified and measures for refining the guideline are developed to minimize the risks due to the inherent issues of specification in the guideline. In a case study, the proposed framework is applied to a typical manufacturing process prone to risks, i.e., forging of aeroengine titanium alloy blades, and the analysis results indicate practicality of the framework, as well as effectiveness of the guideline refinements.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
References
Alper SJ, Karsh BT (2009) A systematic review of safety violations in industry. Accid Anal Prev 41(4):739–754
Alur R (1998) Model checking of hierarchical state machines. Acm Sigsoft Softw Eng Notes 23(6):273–303
Armando A, Compagna L (2004) SATMC: a SAT-based model checker for security protocols. In: Proceedings of the logics in artificial intelligence, European Conference, Lisbon, Portugal, 27–30 September 2004
Bengtsson J, Larsen KG, Larsson F, Pettersson P, Wang Y (1996) UPPAAL: a tool suite for the automatic veri cation of real-time systems. Lect Notes Comput Sci 1066:232–243
Carvalho PVRD (2011) The use of functional resonance analysis method (FRAM) in a mid-air collision to understand some characteristics of the air traffic management system resilience. Reliab Eng Syst Saf 96(11):1482–1498
Chen C, Zeng F, Lu M (2015) A verification method for software safety requirement by combining model checking and FTA. In: Proceedings of the 2015 international industrial informatics and computer engineering conference, Xian, Shannxi, China
Cimatti A, Clarke E, Giunchiglia E, Giunchiglia F, Pistore M, Roveri M, Sebastiani R, Tacchella A (2002) Nusmv 2: an opensource tool for symbolic model checking. International conference on computer aided verification. Springer, Berlin, Heidelberg, pp 359–364
Clarke EM, Wing JM (1996) Formal methods: state of the art and future directions. ACM Comput Surv 28(4):626–643
Clay-Williams R, Hounsgaard J, Hollnagel E (2015) Where the rubber meets the road: using FRAM to align work-as-imagined with work-as-done when implementing clinical guidelines. Implement Sci 10(1):1–8
Dadkhah SM, Golbabaei F, Malakootikhah J, Mohamadfam I (2012) Appropriateness criteria for choosing proper risk assessment model of nanomaterial manufacturing processes. Asian J Chem 24(8):3719-23(8):3719–3723
Hajji A, Gharbi A, Pellerin R (2010) Joint production control and product quality decision making in a failure prone multiple-product manufacturing system. Int J Prod Res 50(13):3661–3672
Herrera IA, Woltjer R (2010) Comparing a multi-linear (STEP) and systemic (FRAM) method for accident analysis. Reliab Eng Syst Saf 95(12):1269–1275
Hill R (2014) FRAM Model Visualiser, version 0.3.2. http://www.functionalresonance.com/onewebmedia/FMV_instructions_0.3.2.pdf
Hollnagel E (2012a) FRAM: the functional resonance analysis method. Ashgate, Farnham
Hollnagel E (2012b) Coping with complexity: past, present and future. Cogn Technol Work 14(3):199–205
Holzmann GJ (1997) The model checker SPIN. IEEE Trans Softw Eng 23(5):279–295
Holzmann G (2003) Spin model checker, the: primer and reference manual. Addison-Wesley Professional, Boston
Johnson KG, Khan MK (2003) A study into the use of the process failure mode and effects analysis (PFMEA) in the automotive industry in the UK. J Mater Process Technol 139(1–3):348–356
Khomenko V (2004) Computing shortest violation traces in model checking based on petri net unfoldings and SAT. The University of Newcastle upon Tyne, Newcastle upon Tyne
Laurence D (2005) Safety rules and regulations on mine sites-the problem and a solution. J Saf Res 36(1):39–50
Leveson N (2012) Engineering a safer world: systems thinking applied to safety. MIT Press, Cambridge
Ma S, Gong G, Han L, Song X (2008) Military task programming based on finite state machine (FSM) decision-making model. In: Proceedings of the Asia simulation conference-international conference on system simulation and scientific computing 1416–1420, Beijing, China
Mccarthy GW (2013) FRAM: the functional resonance analysis method, modeling complex socio-technical systems. Aviat Space Environ Med 84(84):1215
Mikos WL, Ferreira JCE, Botura PEA, Freitas LS (2011) A system for distributed sharing and reuse of design and manufacturing knowledge in the PFMEA domain using a description logics-based ontology. J Manuf Syst 30(3):133–143
Ministry of Aerospace Industry of the PRC (1992) HB 6623.1-29, The method for measuring the transition temperature β of titanium alloy: Differential Thermal Analysis. Beijing: Ministry of Aerospace Industry Standard Issue Department, China
Rivera-Gómez H, Gharbi A, Kenné JP (2013) Production and quality control policies for deteriorating manufacturing system. Int J Prod Res 51(11):3443–3462
Rosa LV, Haddad AN (2015) Assessing risk in sustainable construction using the Functional Resonance Analysis Method (FRAM). Cogn Technol Work 17(4):559–573
Ruijs TC (2001) Towards effective model checking. Universiteit Twente, Enschede
Simpson G, Horberry T, Joy J (2009) Understanding human error in mine safety. Ashgate, Farnham
The Commission of Science, Technology and Industry for National Defense (COSTIND) of the PRC (2008) GJB 494A-2008, Specification for titanium alloy bars for aeroengine compressor blade. Beijing: COSTIND Military Standard Issue Department, China
Tian J, Wu J, Yang Q, Zhao T (2016) FRAMA: a safety assessment approach based on Functional Resonance Analysis Method. Saf Sci 85:41–52
Venkatasubramanian V, Zhao J, Viswanathan S (2000) Intelligent systems for HAZOP analysis of complex process plants. Comput Chem Eng 24(9):2291–2302
Xin JY, Lin C, Yang QU (2004) Research on model-checking based on petri nets. J Softw 15(9):1265–1276
Xu D, El-Ariss O, Xu W (2010) Testing aspect-oriented programs with finite state machines. Softw Test Verif Reliab 22(4):267–293
Yang J, Su K, Chen Q (2008) Improving encoding efficiency for bounded model checking. IFIP/IEEE International Symposium on Theoretical Aspects of Software Engineering, Washington
Acknowledgments
The authors would like to thank the support of the National Natural Science Foundation of China (No. NSFC-61403009), from a project of Ministry of Industry and Information Technology of China (No. JSZL2014601B004), and from Civil Aviation Joint Funds granted by National Natural Science Foundation of China and Civil Aviation Administration of China (No. U1533201).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Zheng, Z., Tian, J. & Zhao, T. Refining operation guidelines with model-checking-aided FRAM to improve manufacturing processes: a case study for aeroengine blade forging. Cogn Tech Work 18, 777–791 (2016). https://doi.org/10.1007/s10111-016-0391-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s10111-016-0391-1