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Hazard - Risk Assessment and Safety

Fakultas
Haris Wahyudi, ST. M.Sc
Teknik

Program Studi
Teknik Mesin
Introduction
• Conventional engineering design uses a deterministic approach.
• In conventional design these uncertainties are handled by
applying a Factor of Safety (FOS).
• In critical design situations such as aircraft, space, and nuclear
applications, it is often necessary to use a probabilistic approach
to better quantify uncertainty and thereby increase reliability
• There are three approaches for incorporating probabilistic
effects in design.
• Methods in order to increase sophistication:
1. The use of a factor of safety
2. The use of the absolute worst case design
3. The use of probability in design

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Design for Reliability
• Reliability is the probability that a system,
component, or device will perform without failure
for a specified period of time under specified
operating conditions
• The malfunctions that an engineering system can
experience can be classified into five general
categories
1. Design mistakes: include all important operating
factors, incomplete information on loads and
environmental conditions, erroneous calculations, and
poor selection of materials
2. Manufacturing defects: Although the design may be
free from error, defects introduced at some stage in
manufacturing may degrade it.

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Design for Reliability
4. Maintenance: Most engineering systems are designed on
the assumption they will receive adequate maintenance at
specified periods. When maintenance is neglected or is
improperly performed, service life will suffer.
5. Exceeding design limits: If the operator exceeds the limits
of temperature, speed, or another variable for which it
was designed, the equipment is likely to fail.
6. Environmental factors: Subjecting equipment to
environmental conditions for which it was not designed,
such as rain, high humidity, and ice, usually greatly
shortens its service life

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Minimizing Failure
• Margin of Safety
– The variability in strength of materials has a major impact on
the probability of failure, so failure can be reduced with no
change in the mean value if the variability of the strength can
be reduced
• Durability
– The material selection and design details should be
performed with the objective of producing a system that is
resistant to degradation from such factors as corrosion,
erosion, foreign object damage, fatigue, and wear
• Damage Tolerance
– Crack detection and propagation have taken on great
importance since the development of the fracture mechanics
approach to design

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Minimizing Failure
• Ease of Inspection
– The importance of detecting cracks should be apparent
– Ideally it should be possible to employ visual methods of
crack detection, but special design features may have to
be provided in order to do so
• Simplicity
– Simplification of components and assemblies reduces
the chance for error and increases the reliability.
• Specificity
– Whenever possible, be specific with regard to material
characteristics, sources of supply, tolerances and
characteristics of the manufacturing process, tests
required for qualification of materials and components,
and procedures for installation, maintenance, and use.
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Importance of Safety in Design
Unintentional injuries
• Cost of $399 billion a year only in the USA
• Fifth leading cause of death
• Due to interaction between machines and their
environment and the way people live and work

Engineers should more think about the

safety of the users...

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Hazard analysis: What is it?
• A hazard is an unsafe condition, which if not
corrected, can reasonably be expected to result
in failure and/or injury
• A hazard is the potential for human, property, or
environmental damage
– cracked steering linkage, a leaking fuel line, or a
loose step all represent hazards
• A risk is the likelihood, expressed either as a
probability or as a frequency, of a hazard’s
materializing
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Hazard analysis: What is it?
• Hazard
– Potentially dangerous condition, which is triggered by an
event, called the cause of the hazard.
• Hazard analysis
– Identify all possible hazards potentially created by a product,
process or application
• Risk
– Hazard that is associated with a severity and a probability of
occurrence.
• Risk assessment
– It is the next step after the collection of potential hazards.
– Risk in this context is the probability and severity of the
hazard becoming reality.

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Six Classes of Hazards to Which Society is Subject

• Categories 3 and 4 are directly within the realm of

responsibility of the engineer
• Categories 2, 5, and possibly 6 provide design
constraints in many situations.
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Hazard analysis: What is it?
• When performed
– Before and during the design begins
• Information used
– Literature
– Scenarios
– Expert opinions
– Personal experience

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Risk Assessment
• General risk assessment protocol
Establish Analysis Parameters

Identify Hazards

Assess Risks

Derive Risk Rating

Reduce Risks

Verify Effectiveness

Document Results
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Risk Assessment
Establish Analysis Parameters These parameters can
be
Identify Hazards
• limits of the machine
Assess Risks or design
• limits on uses
Derive Risk Rating
• limits on the scope of
Reduce Risks the analysis
Verify Effectiveness
• or other limits

Document Results

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Risk Assessment
Establish Analysis Parameters
The nature of this step
Identify Hazards
lends itself to a team
approach such as
Assess Risks brainstorming
Derive Risk Rating

Reduce Risks

Verify Effectiveness

Document Results

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Risk Assessment
Establish Analysis Parameters • Two (2) risk factors
Identify Hazards
are used:
– severity of injury
Assess Risks
– probability of occurrence
Derive Risk Rating

Reduce Risks

Verify Effectiveness

Document Results

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Risk Assessment
Establish Analysis Parameters Risk matrix
Identify Hazards

Assess Risks

Derive Risk Rating

Reduce Risks

Verify Effectiveness
If the risk is determined to be not
acceptable, it is necessary to reduce that
Document Results risk by implementing protective measures.

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Example of Risk Matrix

Negligible Marginal Critical Catastrophic

Certain Stubbing Toe

Minor Car
Likely
Accident

Major Car
Possible
Accident

Unlikely Aircraft Crash

Rare Major Tsunami

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Risk Assessment
Establish Analysis Parameters
• Remedy actions are taken
Identify Hazards
to reduce risks following
the hazard hierarchy:
Assess Risks – Eliminate hazards through
the design
Derive Risk Rating
– Protect
Reduce Risks – Warn the user
– Train the user(s)
Verify Effectiveness
– Personal protective
Document Results equipment

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Risk Assessment
Establish Analysis Parameters • This assessment
verifies that the
Identify Hazards
remedy actions have
Assess Risks reduced the risks to an
acceptable level.
Derive Risk Rating

Reduce Risks

Verify Effectiveness

Document Results

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Risk Assessment
Establish Analysis Parameters
• The documentation can
Identify Hazards
be added to a technical
file for future use.
Assess Risks

Derive Risk Rating

Reduce Risks

Verify Effectiveness

Document Results

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Risk Assessment
• When to stop?
– There is no zero risk, always some residual
risk remains.
– If the residual risk is acceptable, then the risk
assessment process is completed.

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What could be the next steps ?
Failure Modes and Effects Analysis (FMEA)
• Identifies potential product modes which could
lead to accidents,
• Breaks down designs into components or sub-
components, then systematically evaluates the
potential for and effects of individual failures,
• Results of the analysis are used to evaluate and
implement preventive measures to eliminate or
control hazards.

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Failure Mode and Effects Analysis (FMEA)
• FMEA is a team-based methodology for
identifying potential problems with new or
existing designs.
• It is one of the most frequently used hazard-
analysis tools.
• FMEA identifies the mode of failure of every
component in a system and determines the
effect on the system of each potential failure
– By failure we mean inability to meet a customer’s
requirements as opposed to actual catastrophic
material breakage or failure.

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FMEA Methodology
• There are many variations in detailed FMEA
methodology, but they are all aimed at
accomplishing three (3) things:
1. Predicting what failures could occur
2. Predicting the effect of the failure on the
functioning of the system
3. Establishing steps that might be taken to prevent
the failure, or its effect on the function
• FMEA is useful in identifying critical areas of the
design that need redundant components and
improved reliability.

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Developing a FMEA
Three factors are considered in developing a FMEA
1. The severity of a failure
– Table 1. gives the scale for rating severity.
– Many organizations require that potential failures with a 9
or 10 rating require immediate redesign.
Table 1. The severity of a failure

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 Developing a FMEA
2. The probability of occurrence of the failure
– Table 2 gives a scale for probability of occurrence.
– The probabilities given are very approximate and depend
on the nature of the failure, the robustness of the design,
and the level of quality developed in manufacturing.
Table 2. The probability of occurrence

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 Developing a FMEA
• Three factors are considered in developing a FMEA:
3. The likelihood of detecting the failure in either design or
manufacturing, before the product is used by the customer
• Table 3. gives the scale for detection.
• Clearly, the rating for this factor depends on the quality review systems in
place in the organization.
Table 3. Rating for Detection of Failure

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 Results of a FMEA Analysis
• Severity (Table 1)
– A = 3, B =4, C = 4
• Occurrence (Table 2)
– A = 4, B = 4, C = 9
• Detection rating (Table 3)

Usual practice is to combine the rating for the three factors into a Risk
Priority Number (RPN)
RPN = (severity of failure) × (occurrence of failure) × (detection
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Defects and Failure Modes
• Failures of engineering designs and systems are a
result of deficiencies in four (4) broad categories.
1. Hardware failure: failure of a component to function as
designed.
2. Software failure: failure of the computer software to
function as designed.
3. Human failure: failure of human operators to follow
instructions or respond adequately to emergency
situations.
4. Organizational failure: failure of the organization to
properly support the system.
• Examples might be overlooking defective components,
slowness to bring corrective action, or ignoring bad news.

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Causes of Hardware Failure
1. Design deficiencies
– Failure to adequately consider the effect of notches
– Inadequate knowledge of service loads and environment
– Difficulty of stress analysis in complex parts and loadings
2. Deficiency in selection of material
– Poor match between service conditions and selection criteria
– Inadequate data on material
– Too much emphasis given to cost and not enough to quality
3. Imperfection in material due to manufacturing
4. Improper testing or inspection
5. Overload and other abuses in service
6. Inadequate maintenance and repair
7. Environmental factors
– Conditions beyond those allowed for in design
– Deterioration of properties with time of exposure to environment

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Failure Modes
• The specific modes of failure of engineering
components can usually be grouped into four (4)
general classes:
1. Excessive elastic deformation
2. Excessive plastic deformation
3. Fracture
4. Loss of required part geometry through corrosion
or wear

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Design for Safety
• There are three (3) aspects to design for safety:
1. Make the product safe, that is, design all hazards
out of the product.
2. If it is not possible to make the product inherently
safe, then design in protective devices like guards,
automatic cutoff switches, and pressure-relief
valves, to mitigate the hazard.
3. If step 2 cannot remove all hazards, then warn the
user of the product with appropriate warnings like
labels, flashing lights, and loud sounds.

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Potential Dangers
• Some of the general categories of safety
hazards that need to be considered in design.
– Acceleration/deceleration: falling objects, whiplash, impact
damage
– Chemical contamination: human exposure or material degradation
– Electrical: shock, burns, surges, electromagnetic radiation, power
outage
– Environment: fog, humidity, lightning, sleet, temperature extremes,
wind
– Ergonomic: fatigue, faulty labeling, inaccessibility, inadequate
controls
– Explosions: dust, explosive liquids, gases, vapors, finely powdered
materials
– Fire: combustible material, fuel and oxidizer under pressure,
ignition source
– Human factors: failure to follow instructions, operator error

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Potential Dangers
• Leaks or spills
• Life cycle factors: frequent startup and shutdown, poor
maintenance
• Materials: corrosion, weathering, breakdown of lubrication
• Mechanical: fracture, misalignment, sharp edges, stability,
vibrations
• Physiological: carcinogens, human fatigue, irritants, noise,
pathogens
• Pressure/vacuum: dynamic loading, implosion, vessel rupture, pipe
whip
• Radiation: ionizing (alpha, beta, gamma, x-ray), laser, microwave,
thermal
• Structural: aerodynamic or acoustic loads, cracks, stress
concentrations
• Temperature: changes in material properties, burns, flammability,
volatility

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Guidelines for Design for Safety
1. Recognize and identify the actual or potential hazards,
and then design the product so they will not affect its
functioning.
2. Thoroughly test prototypes of the product to reveal any
hazards overlooked in the initial design.
3. Design the product so it is easier to use safely than
unsafely.
4. If field experience turns up a safety problem, determine
the root cause and redesign to eliminate the hazard.
5. Realize that humans will do foolish things, and allow for it
in your design
– More product safety problems arise from improper product
use than from product defects.
– A user-friendly product is usually a safe product.

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Guidelines for Design for Safety
6. There is a close correspondence between good
ergonomic design and a safe design. For example:
– Arrange the controls so that the operator does not have
to move to manipulate them.
– Make sure that fingers cannot be pinched by levers or
other features.
– Avoid sharp edges and corners.
– Point-of-operation guards should not interfere with the
operator’s movement.
– Products that require heavy or prolonged use should be
designed to avoid cumulative trauma disorders like
carpal tunnel syndrome. This means avoiding awkward
positions of the hand, wrist, and arm and avoiding
repetitive motions and vibration.

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Guidelines for Design for Safety
7. Minimize the use of flammable materials, including packaging
materials.
8. Paint and other surface finishing materials should be chosen
to comply with EPA* and OSHA* regulations for toxicity to the
user and for safety when they are burned, recycled, or
discarded.
9. Think about the need for repair, service, or maintenance.
Provide adequate access without pinch or puncture hazards to
the repairer.
10.Electrical products should be properly grounded to prevent
shock. Provide electrical interlocks so that high-voltage
circuits will not be energized unless a guard is in the proper
position.
– EPA: Environmental Protection Agency
– OSHA: Occupational Safety and Health Administration

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Terima Kasih
Haris Wahyudi, ST. M.Sc