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etc.[VisualPro Tech Insight] Building Fault Tree Analysis (FTA) Structures in a Single Step with AI Assistance

In our previous VisualPro Tech Insight, we demonstrated how to seamlessly transition into an FMEA analysis based on the results of an STPA (Systems Theoretic Process Analysis) that identified hidden threats within a semiconductor fab.

This time, we will demonstrate how to construct an FTA structure based on those FMEA analysis results, as well as how to build an initial FTA structure using nothing more than an image of a system architecture.

VisualPro FMEA screen — failure mode, effect and cause table for the semiconductor fab safety equipment with an item-edit dialog


1. Constructing FTA from FMEA Data

First, we will take the results of the "semiconductor manufacturing process safety equipment" analysis—which previously progressed from STPA to FMEA—and construct it directly into an FTA structure.


Claude Desktop conversation — a request to build an FTA from the semiconductor DFMEA results and the reply laying out a Top Event with AND/OR gates and basic events


  • We will utilize the Sonnet 4.6 adaptive model on Claude Desktop for this process.

  • The FTA structure is built based on the currently completed FMEA.

  • We established the tree structure of the FTA using a bottom-up approach, based entirely on the causal relationships identified in the FMEA analysis.

  • You can see that the conversion from FMEA to FTA within VisualPro is executed effortlessly with a single command to the AI, bypassing any cumbersome procedures.


FTA tree drawn in VisualPro — worker casualties and environmental pollution as the Top Event, gates GT1–GT3 leading to basic events EVT1–EVT3 (failure to detect gas leak, pressure measurement error or sensor failure, failure to shut off valve) with probabilities


Recalling the previous conversion of the VisualPro STPA analysis into FMEA, we can see a continuous, streamlined conversion flow: from STPA to FMEA, and then from FMEA to FTA.



2. Constructing FTA from System Architecture Images

Next, we will proceed with constructing an FTA using only an image of the system architecture. This is possible because recent AI models feature advanced vision capabilities that allow them to recognize and interpret images.


Motor control system architecture block diagram — Joystick Monitor, CAN Data Receiver, Motor Current Receiver and other input modules feeding WinControlDecisionMaker, then PWM DutySetter and H-bridge IPS Driver, with the PositionState fault path highlighted in red


  • For this analysis, we will build the FTA using a system architecture of a virtual "Window Lift Motor".

  • Similarly, we will utilize Claude Desktop's Sonnet 4.6 adaptive model.

Claude Desktop conversation — a prompt asking to build an FTA from the architecture image alone, and the reply organizing the FTA into Level 1–4 gates


  • The prompt can be provided simply, as illustrated in the figure.

  • The FTA structure was successfully constructed based solely on the architecture image.

FTA tree auto-generated from the architecture image — a top event branching into 6 gates and 15 basic events over four levels


  • We can confirm that the details of the events and gates have been mapped and inserted with logical accuracy.


Summary of the generated FTA structure — Window Lift System Failure (GT1) with motor drive failure, input signal processing failure, motor output chain failure, pinch detection failure and safety protection circuit failure gates and basic events EVT1–EVT15; 6 gates and 15 events in total


Conclusion

In this way, VisualPro leverages AI features to assist analysts in setting up initial analysis environments much more easily, a process that is traditionally cumbersome and difficult.


※ Note: This analysis was conducted using the AI model connection feature via MCP within the VisualPro FTA environment, and was written in connection with existing analyses.