Analysis of risks related to the use of artificial intelligence in production planning and control processes using fuzzy FMEA
Published 2026-03-25
Keywords
- Production Planning and Control, Artificial Intelligence Risks, Fuzzy FMEA
- Üretim Planlama ve Kontrol, Yapay Zekâ Riskleri, Bulanık FMEA
How to Cite
Copyright (c) 2026 Zafer Duran

This work is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.
How to Cite
Abstract
Production planning and control (PPC) processes are increasingly subject to uncertainty due to growing system complexity, variable demand, and the integration of data-driven decision-support tools. Artificial intelligence (AI)-supported tools provide significant conveniences in managing this uncertainty, but also give rise to new risks that are difficult to control. However, the literature mainly addresses the risks posed by AI in PPC in a scattered manner through different concepts, and comprehensive approaches that holistically assess these risks remain limited. This study aims to address this gap in the literature by assessing the risks arising from the use of AI in PPC applications using Fuzzy Failure Mode and Effects Analysis (Fuzzy FMEA). In this context, the nine risk factors within the scope of the study were analysed using linguistic assessments by 14 academics specialising in PPC, with respect to probability, severity, and detectability. The analysis results identified cybersecurity, lack of explainability, and algorithmic bias as the most significant risks associated with AI use in PPC applications. The study offers a structured risk-prioritisation approach under uncertainty, providing a guiding framework for a more controlled and sustainable integration of AI into PPC processes.
References
- Bécue, A., Praça, I., & Gama, J. (2021). Artificial intelligence, cyber-threats and Industry 4.0: Challenges and opportunities. Artificial Intelligence Review, 54(5), 3849-3886. https://doi.org/10.1007/s10462-020-09942-2
- Burggräf, P., Wagner, J., & Koke, B. (2018, January 12-14). Artificial intelligence in production management: A review of the current state of affairs and research trends in academia [Conference paper]. 2018 International conference on information management and processing (ICIMP), London, IEE, p. 82-88. https://doi.org/10.1109/ICIMP1.2018.8325846
- Cadavid, J. P. U., Lamouri, S., Grabot, B., & Fortin, A. (2019). Machine learning in production planning and control: A review of empirical literature. IFAC-PapersOnLine, 52(13), 385-390. https://doi.org/10.1016/j.ifacol.2019.11.155
- Cardiel-Ortega, J. J., & Baeza-Serrato, R. (2023). Failure mode and effect analysis with a Fuzzy Logic approach. Systems, 11(7), 348. https://doi.org/10.3390/systems11070348
- Caristi, G., Barilla, D., Morabito, M., & Ferrara, M. (2025). Industrial processes and energy storage: modelling and optimising risk priority number and recovery time objective. Decisions in Economics and Finance, 1-35. https://doi.org/10.1007/s10203-025-00544-7
- Carpanzano, E., & Knüttel, D. (2022). Advances in artificial intelligence methods applications in industrial control systems: Towards cognitive self-optimising manufacturing systems. Applied Sciences, 12(21), 10962. https://doi.org/10.3390/app122110962
- Chang, K. H., Cheng, C. H., & Chang, Y. C. (2010). Reprioritisation of failures in a silane supply system using an intuitionistic fuzzy set ranking technique. Soft Computing, 14(3), 285-298. https://doi.org/10.1007/s00500-009-0403-7
- Chen, E., Luo, X., Ma, X., Bai, X., & Luo, J. (2025). Weight-embedded fuzzy FMEA framework for enhanced risk prioritisation of offshore wind turbines. Ocean Engineering, 341, 122649. https://doi.org/10.1016/j.oceaneng.2025.122649
- Colangelo, E., Fries, C., Hinrichsen, T. F., Szaller, Á., & Nick, G. (2022). Maturity model for AI in smart production planning and control system. Procedia CIRP, 107, 493-498. https://doi.org/10.1016/j.procir.2022.05.014
- Dağsuyu, C., Göçmen, E., Narlı, M., & Kokangül, A. (2016). Classical and fuzzy FMEA risk analysis in a sterilisation unit. Computers & Industrial Engineering, 101, 286-294. https://doi.org/10.1016
- /j.cie.2016.09.015
- de Aguiar, J., Scalice, R. K., & Bond, D. (2018). Using fuzzy logic to reduce risk uncertainty in failure modes and effects analysis. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 40(11), 516. https://doi.org/10.1007/s40430-018-1437-5
- Del Gallo, M., Mazzuto, G., Ciarapica, F. E., & Bevilacqua, M. (2023). Artificial intelligence to solve production scheduling problems in real industrial settings: systematic literature review. Electronics, 12(23), 4732. https://doi.org/10.3390/electronics12234732
- Elbasheer, M., Longo, F., Nicoletti, L., Padovano, A., Solina, V., & Vetrano, M. (2022). Applications of ML/AI for decision-intensive tasks in production planning and control. Procedia Computer Science, 200, 1903-1912. https://doi.org/10.1016/j.procs.2022.01.391
- Fabrocini, F., Jian'an S. (2021). Intelligent process automation of industries using artificial intelligence and machine learning. Journal of Computing and Natural Science, 1(2), 45-56. https://doi.org/
- 10.53759/181X/JCNS202101009
- Fries, M., Nießner, J., Ludwig, T., & Kotthaus, C. (2025). Exploring AI integration in SME production planning: design spaces and the role of workers. Computer Supported Cooperative Work (CSCW), 1-38. https://doi.org/10.1007/s10606-025-09512-6
- Gabsi, A. E. H. (2024). Integrating artificial intelligence in industry 4.0: insights, challenges, and future prospects–a literature review. Annals of Operations Research, 1-28. https://doi.org/10.1007/s10479-024-06012-6
- Godinho Filho, M., de Almeida, S. V. Q., Lage Junior, M., Osiro, L., Lima, B., & Callefi, M. H. (2025). A path to follow to overcome foundational barriers to the adoption of artificial intelligence within the manufacturing industry: a conceptual framework. Enterprise Information Systems, 19(1-2), 2458685. https://doi.org/10.1080/17517575.2025.2458685
- González Rodríguez, G., Gonzalez-Cava, J. M., & Méndez Pérez, J. A. (2020). An intelligent decision support system for production planning based on machine learning. Journal of Intelligent Manufacturing, 31(5), 1257-1273. https://doi.org/10.1007/s10845-019-01510-y
- Guo, Z., & Li, R. (2024). AI-driven risk management for sustainable enterprise development: a review of key risks. International Journal of Business and Management, 19(6), 1-82. https://doi.org/
- 10.5539/ijbm.v19n6p82
- Gupta, G., Ghasemian, H., & Janvekar, A. A. (2021). A novel failure mode effect and criticality analysis (FMECA) using fuzzy rule-based method: A case study of industrial centrifugal pump. Engineering Failure Analysis, 123, 105305. https://doi.org/10.1016/j.engfailanal.2021.105305
- Ilbahar, E., Karaşan, A., Cebi, S., & Kahraman, C. (2018). A novel approach to risk assessment for occupational health and safety using Pythagorean fuzzy AHP & fuzzy inference system. Safety Science, 103, 124-136. https://doi.org/10.1016/j.ssci.2017.10.025
- Kahraman, C., Kaya, İ., & Şenvar, Ö. (2013). Healthcare failure mode and effects analysis under fuzziness. Human and Ecological Risk Assessment: An International Journal, 19(2), 538-552. https://doi.org/10.1080/10807039.2012.737753
- Kunecová, J., Prester, J., Šebo, J., & Palčič, I. (2025). Why do manufacturing firms struggle with artificial intelligence?. Journal of Manufacturing Technology Management, 1-22. https://doi.org/
- 10.1108/JMTM-05-2025-0432
- Laska, M., & Karwala, I. (2023). Artificial intelligence in the chemical industry–risks and opportunities. Zeszyty Naukowe. Organizacja i Zarządzanie/Politechnika Śląska, 172, 403-416. http://dx.doi.org/10.29119/1641-3466.2023.172.25
- Mao, S., Wang, B., Tang, Y., & Qian, F. (2019). Opportunities and challenges of artificial intelligence for green manufacturing in the process industry. Engineering, 5(6), 995-1002. https://doi.org/10.1016/
- j.eng.2019.08.013
- Mäule, J., & Götte, G. (2025). Production planning and control in industry 4.0: overview on challenges of data-driven PPC systems. IFAC-Papers On Line, 59(10), 1253-1258. https://doi.org/10.1016/
- j.ifacol.2025.09.211
- Oluyisola, O. E., Sgarbossa, F., & Strandhagen, J. O. (2020). Smart production planning and control: Concept, use-cases and sustainability implications. Sustainability, 12(9), 3791. https://doi.org/10.3390/su12093791
- Palinkas, L. A., Horwitz, S. M., Green, C. A., Wisdom, J. P., Duan, N., & Hoagwood, K. (2015). Purposeful sampling for qualitative data collection and analysis in mixed method implementation research. Administration and Policy in Mental Health and Mental Health Services Research, 42(5), 533-544. https://doi.org/10.1007/s10488-013-0528-y
- Plathottam, S. J., Rzonca, A., Lakhnori, R., & Iloeje, C. O. (2023). A review of artificial intelligence applications in manufacturing operations. Journal of Advanced Manufacturing and Processing, 5(3), e10159. https://doi.org/10.1002/amp2.10159
- Rezaee, M. J., Yousefi, S., Valipour, M., & Dehdar, M. M. (2018). Risk analysis of sequential processes in food industry integrating multi-stage fuzzy cognitive map and process failure mode and effects analysis. Computers & Industrial Engineering, 123, 325-337. https://doi.org/10.1016/j.cie.2018.07.012
- Roblek, M., Kern, T., Andrašec, E. K., & Brezavšček, A. (2024). Comparative analysis of human and artificial intelligence planning in production processes. Processes, 12(10), 2300. https://doi.org/
- 10.3390/pr12102300
- Seeger, P. M., Yahouni, Z., & Alpan, G. (2022). Literature review on using data mining in production planning and scheduling within the context of cyber physical systems. Journal of Industrial Information Integration, 28, 100371. https://doi.org/10.1016/j.jii.2022.100371
- Sinha, S., & Lee, Y. M. (2024). Challenges with developing and deploying AI models and applications in industrial systems. Discover Artificial Intelligence, 4(1), 55. https://doi.org/10.1007/s44163-024-00151-2
- Soltanali, H., Rohani, A., Abbaspour-Fard, M. H., Parida, A., & Farinha, J. T. (2020). Development of a risk-based maintenance decision making approach for automotive production line. International Journal of System Assurance Engineering and Management, 11(1), 236-251. https://doi.org/
- 10.1007/s13198-019-00927-1
- Testik, O. M., & Unlu, E. T. (2023). Fuzzy FMEA in risk assessment for test and calibration laboratories. Quality and Reliability Engineering International, 39(2), 575-589. https://doi.org/10.1002/qre.3198
- Toptancı, Ş., & Aktaş Potur, E. (2021). Bulanık bütünleşik çok ölçütlü karar verme modeli ile arsa seçimi. Veri Bilimi, 4(3), 106-112. https://izlik.org/JA37NG59ZR
- Usuga Cadavid, J. P., Lamouri, S., Grabot, B., Pellerin, R., & Fortin, A. (2020). Machine learning applied in production planning and control: a state-of-the-art in the era of industry 4.0. Journal of Intelligent Manufacturing, 31(6), 1531-1558. https://doi.org/10.1007/s10845-019-01531-7
- Valiyev, K., & Mahmudova, S. (2025). The challenges and risks of artificial intelligence and their impact on society. ScienceRise, (1), 71-77. https://doi.org/10.21303/2313-8416.2025.003834
- Vyhmeister, E., Gonzalez-Castane, G., & Östbergy, P. O. (2023). Risk as a driver for AI framework development on manufacturing. AI and Ethics, 3(1), 155-174. https://doi.org/
- 10.1007/s43681-022-00159-3
- Wan, J., Li, X., Dai, H. N., Kusiak, A., Martinez-Garcia, M., & Li, D. (2021). Artificial-intelligence-driven customised manufacturing factory: key technologies, applications, and challenges. Proceedings of the IEEE, 109(4), 377-398. https://doi.org/10.1109/JPROC.2020.3034808.
- Wang, Y. M., Chin, K. S., Poon, G. K. K., & Yang, J. B. (2009). Risk evaluation in failure mode and effects analysis using fuzzy weighted geometric mean. Expert Systems with Applications, 36(2), 1195-1207. https://doi.org/10.1016/j.eswa.2007.11.028
- Zhang, Z., & Chu, X. (2011). Risk prioritisation in failure mode and effects analysis under uncertainty. Expert Systems with Applications, 38(1), 206-214. https://doi.org/10.1016/j.eswa.
- 2010.06.046


