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  • 1.  Use of AI in Failure Modes and Effects Analysis

    Posted 09-14-2023 09:48

    Two recent editorials in the ASM Journal of Failure Analysis and Prevention have addressed the potential use of AI language model tool, such as ChatGPT, to support failure modes and effects analysis (FMEA).

    Dan Thomas, Revolutionizing Failure Modes and Effects Analysis with ChatGPT: Unleashing the Power of AI Language Models. Journal of Failure Analysis and Prevention. Vol 23, 2023, p 911–913. https://doi.org/10.1007/s11668-023-01659-y

    Partha Pratim Ray, Transforming Industrial Reliability: The Intersection of Failure Modes and Effects Analysis with Artificial Intelligence. Journal of Failure Analysis and Prevention, Vol 23, 2023, p 1383–1384. https://doi.org/10.1007/s11668-023-01697-6

    Access to the articles is open to all readers through September 30.

    Dan Thomas notes that

    Traditional FMEA methods are often time-consuming and labor-intensive, requiring significant expertise and knowledge to be effective. Recent advancements in artificial intelligence (AI) and machine learning (ML) have opened new possibilities for FMEA, allowing organizations to harness the power of language models like ChatGPT to transform their FMEA process and unlock new insights.

    He reviews how these models can be trained on FMEA data and then help identify potential failure modes for a given system or process, assess risks, and recommend mitigation strategies. He concludes that:

    The potential of ChatGPT in FMEA is just beginning to be realized, and the future looks bright. As more organizations adopt AI and ML technologies, we can expect to see even greater improvements in the efficiency, accuracy, and effectiveness of FMEA processes.

    The editorial by Partha Pratim Ray adds a cautionary note:

    While the integration of AI undoubtedly has potential, any reliance on it should be tempered by a recognition of the limitations of such models. No AI, not even one as advanced as ChatGPT, can wholly supplant the nuanced understanding and judgement calls offered by human experts.

    Dr. Ray argues for an integrated approach, where AI tools are used to supplement human intelligence, leveraging the capacity of these tools to process large amounts of data, thereby freeing the human failure analysis professional to focus on more complex tasks. Their combined efforts should foster "greater efficiency and, ultimately, reliability."

    What are your thoughts about the opportunities and risks of using AI tools in failure analysis?



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    Scott Henry
    Senior Content Engineer
    ASM International
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    FAS - education


  • 2.  RE: Use of AI in Failure Modes and Effects Analysis

    Posted 10-26-2023 14:52

    It scares me to death.

    Using this technology will speed the rapid demise of people knowing how to store and use knowledge as the foundation of analysis and creativity. I have thought and thought about this, and I don't see how this will make us smarter or help us evolve to a new level of true humanity.



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    Debbie Aliya
    Aliya Analytical Incorporated
    Grand Rapids MI
    (616) 475-0059
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    FAS - education


  • 3.  RE: Use of AI in Failure Modes and Effects Analysis

    Posted 01-04-2024 16:56

    Hi Debbie, 

    I can understand your fear of AI, but I think that it will quickly produce possible results and causes which humans then can use to correctly decide (hopefully) the exact cause of failure. People often say to me, AI will do away with so many jobs, but I always ask, what AI produces,,,,,, how do we know it is right? We have to check it. Computers as you know are used extensively on aircraft and fly a lot of the flight, but we still have pilots making sure it is doing what it is supposed to do! I don't think I will get up on a plane with Mr AI flying it and no pilots. Terra ferma comes first in that scenario! Jim     



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    James Dwan
    Professor, MEng.C.Eng Eur Ing FIEI FIMMM MWeldI
    Trinity College Dublin Univ of Dublin, Dwan Forensic Engineering
    Dublin 6
    +353872362895
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    FAS - education


  • 4.  RE: Use of AI in Failure Modes and Effects Analysis

    Posted 01-07-2024 10:12

    I put this prospective out there neither in defense nor condemnation of the use of AI in fmea. Consider, did the introduction of electronic calculators make us dummer. Or computers with the myriad of programs. And now AI. They are all tools susceptible to input and programming deficiencies. We learned garbage in garbage out. We must not blindly follow the output. That's where human knowledge and experience will be necessary. 



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    Joe Epperson, FASM
    Senior Metallurgist, retired
    Waldorf, MD
    Joedirt3478@outlook.com
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    FAS - education


  • 5.  RE: Use of AI in Failure Modes and Effects Analysis

    Posted 01-08-2024 08:29

    I totally agree Joe. Actually a recent study on the use of AI in diagnosing medical paediatric case studies and the AI failed to correctly diagnose the cause close to or more than 80% of the time. So, people are still needed to check AI results. As I say, 'How do we know what AI says is correct?' We need to check it. Blindly believing it will lead to errors. 

    Jim 



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    James Dwan
    Professor, MEng.C.Eng Eur Ing FIEI FIMMM MWeldI
    Trinity College Dublin Univ of Dublin, Dwan Forensic Engineering
    Dublin 6
    +353872362895
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    FAS - education


  • 6.  RE: Use of AI in Failure Modes and Effects Analysis

    Posted 01-08-2024 11:58

    I think that failure analysis materials engineers can not full be replaced, since we can see either macro surface defects or obscure machining + zinc plating defects that no DFMEA could have predicted.  I can think of two examples before I retired:

    1.) A formed & rolled clamp band that failed under PPAP approval fatigue testing in the lab.  The ID side of tensile bending side had a huge scratch from the stamping operation that created a significant fatigue crack initiation site.  Checking chemistry & micros would not have observed the scratch.

    2.) A free-machining grade steel shaft with numerous geometry features and some what sharp fillet radii.  The failure location was one of the sharpest radii, that was made worse be a.) A large MnS inclusion located at the fillet, and b.) When the electro-plater ran a reverse polarity oxide cleaning cycle to remove surface oxides--- the process actually etched away the MnS entirely and created a very sharp notch.  I think I predicted the stress intensity factor some thing like a 4.0 using PETERSON'S STRESS INTENSITY FACTOR HANDBOOK.  The engineering design team spent well over 20 manhours in the DFMEA meeting, where as I had already looked at a few failures that had come through our warranty department, and they did not invite me to the meeting...  

    I do not think AI could have predicted either defect.



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    Patrick Mizik
    ASM Chapter Council Chair & District 11 Rep
    Owner
    Patrick Mizik Engineering, LLC
    pmizik.ks@outlook.com
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    FAS - education