Risk Analysis of Digital Twin Project Operation Based on Improved FMEA Method

With the advent of digitization, digital twin technology is gradually becoming one of the core technologies of the Industry 4.0 era, highlighting the increasing importance of digital twin project management. Despite its potential, DT projects face significant risks during implementation, stemming from technical, managerial, and operational complexities. To address these challenges, this study proposes an improved failure mode and effect analysis (FMEA) framework by integrating double hierarchy hesitant fuzzy linguistic term sets (DHHFLTSs) and the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). This framework converts qualitative assessments into quantitative metrics and calculates weights using a hybrid approach, enabling more precise risk prioritisation. Application of the model to an automotive manufacturing company’s DT project identified key risks, particularly in the iteration and upgrade phase, emphasising the importance of cross-departmental collaboration and robust digital infrastructure. The proposed model provides a systematic framework for enterprises to assess and mitigate risks, ensuring the successful deployment of DT projects.