Safety Through Design

Bruce W. Main, PE CSP design safety engineering, inc. Ann Arbor, Michigan
10 Sept 2003

Presentation Overview

Safety through design

Why you should care Risk assessment basics designsafe demonstration and hints Examples

Safety Through Design...

Design - optimizing against criteria

Late changes in criteria - safety

Getting it right the first time

Familiar Methods

Government regulations (OSHA, FDA, etc.)

Industry standards Checklists Safety factors

Recent Advances

FMEA

Failure Modes & Effects Analysis Component failures

Risk assessment

People failures

Safety Through Design

Getting it right the first time

How?

Risk assessment

Why you should care

Your professors think its a good idea

Your grade depends on it

Other reasons to care

Industry standards are requiring risk assessment

Europe - CE mark requires risk assessment Customers are beginning to require risk assessment

Condition of sale

Lots of momentum in industry in risk assessment

Risk assessment works

Better, cheaper, faster, more productive

The Basics...

The Safety Hierarchy

Forms the theoretical basis for design safety
The preferred approach to addressing hazards is: 1. 2. 3. 4. 5. 6. Eliminate the hazard by design Substitute less hazardous work methods or materials Incorporate safety devices (guarding systems) Provide warning systems Apply administrative controls (work methods, training) Provide personal protective equipment (PPE)

(Manuele: Innovations in Safety Management 2001)

1. Determine the limits of the Machine

2. Hazard Identification
3. Risk Estimation 4. Risk Evaluation 5. Risk Reduction (Countermeasures) 6. Verify Implementation

ANSI B11 TR3

7. Document Results

Hazard Analysis...

Identify hazards

Task-based is a very useful approach

Focuses on what people do

Users/tasks/hazards
Brainstorming grounded in reality

Risk Assessment...

Qualitative / semi-quantitative / quantitative

Working to achieve acceptable risk

risk which remains after protective measures have been taken

risk which is accepted in a given context

Zero risk does not exist

B11 TR3 Matrix

Probability of Occurrence of Harm Catastrophic
Very Likely Likely Unlikely Remote High High Medium Low

Level of Severity
Serious High High Medium Low Moderate High Medium Low Negligible Minor Medium Low Negligible Negligible

MIL-STD-882D Matrix
CATEGORY
FREQUENCY (A) FREQUENT ( X > 10-1 ) (B) PROBABLE ( 10-1 > X > 10-3 ) (C) OCCASIONAL ( 10-2 > X 10-3 ) (D) REMOTE ( 10-3 > X > 10-6 ) (E) IMPROBABLE ( 10-6 > X ) (1) CATASTROPHIC (2) CRITICAL (3) MARGINAL (4) NEGLIGIBLE

UNACCEPTABLE UNDESIRABLE

ACCEPTABLE WITH REVIEW ACCEPTABLE WITHOUT REVIEW

R15.06 Matrix
SEVERITY OF INJURY EXPOSURE AVOIDANCE A2 Not Likely A1 Likely A2 Not Likely A1 Likely A2 Not Likely A1 Likely A2 Not Likely A1 Likely RISK REDUCTION CATEGORY

S2 Serious Injury More than First-aid

E2 Frequent exposure

R1 R2A R2B R2B R2C R3A R3B R4

E1 Infrequent exposure

S1 Slight Injury First-aid

E2 Frequent exposure

E1 Infrequent exposure

Table 2 Risk reduction decision matrix prior to safeguard selection

HFMEA Hazard Scoring Matrix

Severity
Catastrophic Major Moderate Minor

Probability

Frequent
Occasional

16
12

12
9

8
6

4
3

Uncommon
Remote

8
4

6
3

4
2

2
1

Risk Scoring Systems

Bringing structure to a subjective analysis There is no one right approach This is subjective Become comfortable with subjectivity The goal is acceptable risk

Risk Assessment Results

New design requirements/criteria !! Assessment of risk: severity/probability ratings Road map for risk reduction activities Framework for solutions (safety hierarchy)

design changes, guarding systems warnings, instructions, training, PPE requirements

Risk reduced to acceptable risk

A Demonstration

designsafe

Key Points about designsafe

Guides you through the risk assessment process Conforms to current standards Helps you identify hazards Prompts your risk reduction effort Creates the documentation Free demo at www.designsafe.com

Too Much Residual Risk? What do you do?

Reduce

Transfer
Avoid Accept

When do we accept risk?

When its insignificantly low. When we are sure it is worth it.

When we do not know it is there.

Tips on using designsafe

It is a guide. Use your head. Keep your eye on the goal

Identify hazards Reduce risks to an acceptable level

Risk scoring is not a scientific exercise. Look for effective shortcuts

All users, all tasks Cut, copy, paste

Make it work for you.

Example Large Oven System

Oven system to bake finish on parts

Elevated, overhead location

Access required from time to time

Service conveyor, oven

Retrieve fallen parts

View Inside of Oven

Fallen Parts

Tripping Hazards

Problems

Lighting insufficient
Access difficult Introduced hazards to the workplace

Task-based risk assessment finds these

Perishable Goods Processing

Packaging system to extend food shelf life

Automated production system in operation

Sales wants small, manual system

customers can try before they buy

Prototype hand-held design in development

Risk assessment performed

New hazards identified

Electrical equipment in wet environment
- not hard wired

Complex/confusing operation
unmarked/confusing controls high probability for operator error equipment damage could occur if not properly done

Hand puncture needle stick

Changes Made

GFI added Design changes to greatly simplify procedures Entirely eliminated need for operator to adjust controls Improved user information manual, warnings, system package Puncture resistant gloves added

Common Themes

Must identify hazards early

Early is better, faster, cheaper and more effective Task based risk assessment helps identify more hazards Allows engineers to reduce risks Risk assessment helps to determine

What, why, how and how much

Review

Safety through design

Why you should care Risk assessment basics Demonstrated the process - designsafe Example risk assessment applications