Abstract

PurposeThis paper aims to provide a systematic review of failure mode and effects analysis (FMEA) research, focusing on the various methods proposed to enhance the traditional FMEA method. The study addresses the limitations of the traditional risk priority number (RPN) method and identifies gaps in the existing literature.Design/methodology/approachA systematic review was conducted on a wide range of studies published between 2004 and 2024. The reviewed papers were categorized based on the methods employed to address the shortcomings of the conventional FMEA approach. The analysis focused on the most frequently cited flaws, the modern tools and technologies used, and the limitations of these approaches.FindingsThe review highlights the most prominent flaws in traditional FMEA, and identifies the most commonly used modern approaches that have been integrated into FMEA to improve its effectiveness and overcome these issues. Additionally, it identifies the limitations of these newer approaches and the research gaps that remain, and provides insights into the strengths and weaknesses of these methods.Originality/valueThis study contributes to the field by offering a structured and systematic review of FMEA research, which has not been comprehensively addressed in prior literature. By synthesizing the findings of numerous studies, this paper provides a clear direction for future research for addressing the existing shortcomings of the traditional RPN model.