Failure mode–driven quality analysis of operational risks for composite fiber-reinforced plastic assembly

Composite fiber-reinforced plastic products have many failure modes in the manufacturing stage. The cost of rework is high. To ensure a reliable manufacturing process and outcome, this article presents a new method to prioritize assembly process errors according to a risk-based cost of poor quality. The method combines a range of reliability techniques including cause–effect diagram, fault tree, and analytic hierarchy process to achieve multiple failure mode assessment. The outcome of this research provides direct links to develop risk mitigation plans to treat the prioritized risks of production errors in the composite fiber-reinforced plastic assembly process.