Quality variation control oriented product infant failure risk mitigation strategy based on risk chain

Infant failure seriously affects customer satisfaction, which is mainly determined by quality variations in manufacturing process, and it is the most critical part of product quality risk. However, most of manufacturers subject to lack of targeted quality variation controlling for infant failure risk, which causes neglecting of preventing and mitigating infant failure risk. Therefore, in this paper, first, an infant failure risk chain is put forward to clarify the formation mechanism from process variation to infant failure. And second, based on forward analysis of the chain, infant failure risk is quantitatively modeled. Third, according to the analysis results, the key process variations are identified by backward analysis of the chain. And variation controlling costs and infant failure losses costs are comprehensively considered to optimize process variation controlling. Finally, a case study of a level control system is introduced to verify the applicability of the proposed method. The final result shows that the proposed method has a good performance in infant failure risk mitigation.