Risk Analysis and

Management
 Risk The probability that a hazard will result in a
specified level of loss
LIKELIHOOD
The likelihood is the chance that the hazardous event will
occur
 CONSEQUENCE
Consequence is the outcome of the hazardous event
RISK MEASUTREMENT

Risk = Likelihood x Consequence

Risk Management- The systematic application of
management policies, procedures, and practices to
the tasks of analyzing, assessing, and controlling risk
in order to protect employees, the general public,
and the environment, as well as company assets,
while avoiding business interruptions.
Acceptable Risk: Risk that has been reduced to a
level that can be tolerated by the organization having
regard to its legal obligations and its own HSE policy.
Risk analysis is the estimation of the risk associated
with the identified hazards, linking the likelihood of
occurrence and severity of harms.
Risk evaluation compares the identified and
analyzed risk against given risk criteria.
Risk communication is the sharing of information about
risk and risk management between the decision makers
and others. Communications might include those among
interested parties (e.g., regulators and industry; industry
and the patient; within a company, industry, or regulatory
authority).

Risk control includes decision making to reduce and/or

accept risks. The purpose of risk control is to reduce the
risk to an acceptable level.

Risk assessment consists of the identification of hazards

and the analysis and evaluation of risks associated with
exposure to those hazards
 5 STEPS OF RISK ASSESSMENT- AS PER NEBOSH
Step 1: Identify the hazards
Step 2: Decide who might be harmed and how
Step 3: Evaluate the risks and decide on precautions
Step 4: Record your findings and implement them
Step 5: Review your risk assessment and update if
necessary
HAZID
HAZID

HAZAN
HAZID- Hazard Identification
Hazid is a high level hazard identification technique
which is commonly applied on an area by area basis to
hazardous installations. Hazid study is the systematic
method of identifying hazards to prevent and reduce any
adverse impact that could cause injury to personnel,
damage or loss of property, environment and production,
or become a liability. It is a component of the risk
assessment and risk management..

HAZAN- Hazard Analysis

Hazan is the identification of undesired events that lead
to the materialization of a hazard, the analysis of the
mechanisms by which these undesired events could occur,
and, usually, the estimation of the consequences
 It is good practice to review your risk assessment on a
regular basis to be sure that nothing has changed and
that your control methods are effective. Triggers for a
review can also include:
The start of a new project.

A change in the work process or flow.

A change or addition to tools, equipment, machinery

(including locations or the way they are used).
New employees.

Moving to a new building or work area.

Introduction of new chemicals or substances.

When new information becomes available about a

current product.
The following methods is generally used for the hazard
identification
What If Analysis

Checklist Analysis

Hazard and Operability Study (HAZOP)

Failure Modes and Effects Analysis (FMEA)

Job Safety analysis

Human error analysis

Safety Review

Past accident report/ Near miss report

All these tools has their unique methodology and these are
to be used as per the requirements. Finally all these
methodologies are aim to minimise the Risk and suggest
mitigation control measures to reach to the acceptable
risk, if not possible to totally eliminate the Risk
 Hazard Identification Techniques
Reactive approach

Accident Investigation

Plant Inspection

Incident Recall Technique

 Proactive approach

Safety Analysis (JSA)

HIRA/HARC/HIRAC
Failure Mode and Effect Analysis (FMEA)
Hazard and Operability Study (HAZOP)
Fault Tree and Event Tree Analysis (FTA
& ETA)
Fire Explosion and Toxicity Index (FETI)
Material / Chemical Reactive Analysis
Consequence analysis (Dispersion
Modelling)
 Incident recall technique
Incident recall is to help people
remember events that could have led
to undesired consequences. These
incidents help to learn from accidents /
incidents.
The interviewing could be done by a
supervisor / manager or by a staff
person
It could be done on a one-on-one basis
or as a group exercise.
JOB HAZARD ANALYSIS
WHAT IS JOB HAZARD ANALYSIS (JHA)?

A method of studying a job

in order to:
(a) Identify hazards or
potential incidents
associated with each step or
task and
(b) Develop solutions that will
eliminate, nullify, or prevent
such hazards or incident
potential
WHEN IS A JHA REQUIRED?

If an existing JHA is not available

Not adequately updated or suited to the job

A JHA is a mandatory requirement for all tasks

that require a Permit to Work to be issued.
JHA TEAM SELECTION
A team of skilled professionals should be used when
developing a JHA, known as the JHA Team:
Line Management (Supervisors)
Employee who has experience
with job
Group Involvement - those
that do the job (Performing
party)
Use safety professionals or
practitioners as guidance &
resource
Emergency management team

Communications
JHA DEVELOPMENT
Five stages of JHA development

Inspect the work site

Breakdown the job into different Tasks

Identify the Hazards for each Task

Assess the Risk for Each Task

Determine the Risk Control Measures and Action Plan

DETERMINE THE RISK CONTROL MEASURES AND ACTION PLAN

Eliminate The Complete Elimination

of the Hazard

Replacing the Material or

REDUCE/REPLACE Process with a less Hazardous
One
Isolating the Hazard
ISOLATE by Guarding or Enclosing

Providing Controls such

ENGINEERING
as automation,lev,etc.
CONTROLS
Use Appropriate and Properly
PPE Fitted PPE where other Controls are not
More Effective practical.
Controls
Administrate Such as trainings, supervision
JHA SIGN OFF AND RECORD
Sign off of the JHA must occur by the involved parties for
the JHA to be considered an accepted document.
Records has to be updated and reviewed.
JHA REVIEW
A JHA must be reviewed the following:

The scope of work changes

Significant change to the work environment
There is an Incident or Near Miss
At least once every two years to remain valid
HIRAC- HAZARD IDENTIFICATION
RISK ASSESSMENT AND CONTROL
HIRAC
HIRAC (Hazard Identification risk assessment and control)

To develop a method for Identification of Occupational

Health and Safety (OHS) hazards, assessment of risks and
determination of necessary control measures to reduce the
risks of injury and ill health
Example- Applied widely in construction industry

To what activity can the HIRAC be applied?

1. Only for Routine Activity
2. Only for Non Routine Activity
3. Both

Non Routine Activity : An activity which can be carried

out only a small period of time.
Example ; Blasting of rock occurs only for few days during
construction
 HIRAC (Hazard Identification risk assessment and control)

People who should participate in HIRAC Process

Project Managers

Functional and departmental Heads

Workmen

Supervisors,

HSE Engineers
SEVERITY FACTOR
PROBABILITY FACTOR
 5*5 Risk Matrix

Determine Risk Level by using S & P factors using the formula given below:
Risk Level = Severity (S) X Probability (P)
PRELIMNARY HAZARD ANALYSIS
 PRELIMINARY HAZARD ANALYSIS
PHA [Preliminary Hazard Analysis] is carried out to identify
and describe Hazards & Threats at earliest stage of the Project
design development.

Example
Consider a pre design concept that feeds H2S (Hydrogen
sulphide)from a pressurized storage cylinder to a process unit. at
this stage of the design , the analyst knows only that this material
will be used in the process , nothing more . The analyst recognizes
that h2s has toxic and flammable properties, and the analyst
identifies the potential release of h2s as a hazardous situation.

The analyst lists the following causes for such a release.

The pressurized storage cylinder leaks or ruptures
The process does not consume all of the h2s
The h2s process supply lines leak/rupture
A leak occurs during connection of a cylinder to the process
 The analyst then determines the effects of these
causes. in this case , fatalities could result from large
releases. The next task is to provide guidance and
design criteria by describing corrective/preventive
measures for each possible release.
The analyst suggests that the designer:.
Consider a process that stores alternative, less toxic materials
that can generate h2s as needed
Consider developing a system to collect and destroy excess h2s
from the process
Provide a plant warning system for h2s releases
Minimize on-site storage of h2s, without requiring excessive
delivery/handling
Develop a procedure using human factors engineering expertise for
storage cylinder connection
Consider a cylinder enclosure with a water deluge system that is
triggered by h2s leak detection
Locate the storage cylinder for easy delivery access, but away from
other plant traffic.
HAZOP (HAZARD OPERABILITY STUDY)
 HAZOP
HAZOP is a hazard analysis technique that
systematically divides a system, equipment, or process
into a series of nodes to identify possible deviations from
normal operations and ensure that appropriate
safeguards are in place to help prevent accidents.
Before the HAZOP study is started, detailed information

on the process must be available.

This includes up-to-date process flow diagrams (PFDs),

process and instrumentation diagrams (P&IDs), detailed

equipment specifications, materials of construction, and
mass and energy balances.
The full HAZOP study requires a committee composed of

a cross-section of experienced plant, laboratory, technical,

and safety professionals. One individual must be a
trained HAZOP leader and serves as the committee chair
 Terminology used in HAZOP Study
a. STUDY NODES - The locations (on piping and
instrumentation drawings and procedures) at which the
process parameters are investigated for deviations.

b. INTENTION - The intention defines how the plant is

expected to operate in the absence of deviations at the study
nodes. This can take a number of forms and can either be
descriptive or diagrammatic; e.g., flow sheets, line diagrams,
P&IDS.

c. DEVIATIONS - These are departures from the intention

which are discovered by systematically applying the guide
words (e.g., "more pressure").
Guide word + Parameter Deviation
d. CAUSES - These are the reasons why deviations might
occur. Once a deviation has been shown to have a
credible cause, it can be treated as a meaningful
deviation. These causes can be hardware failures,
human errors, an unanticipated process state (e.g.,
change of composition), external disruptions (e.g., loss
of power), etc.

e. CONSEQUENCES - These are the results of the

deviations should they occur (e.g., release of toxic
materials). Trivial consequences, relative to the study
objective, are dropped.

f. GUIDE WORDS - These are simple words which are

used to qualify or quantify the intention in order to
guide and stimulate the brainstorming process and so
discover deviations.
PARAMETERS
Application of parameters will depend on the type
of process being considered, the equipment in the
process and the process intent.
Pressure

Temperature

Flow

Voltage

Ph

Velocity

Viscosity

Corrosion
DEVIATION
High temperature
Low temperature

High viscosity

Low flow

High flow

Reverse flow
 3 CAUSES OF DEVIATION
1. Human Error - acts of omission or commission by an
operator, designer, constructor or other person
creating a hazard that could possibly result in a
release of hazardous or flammable material.
Example- Operator failed to close the value on time
2. Equipment failure in which a mechanical, structural
or operating failure results in the release of hazardous
or flammable material. Example- Failure of a pump
3. External Events in which items outside the unit
being reviewed affect the operation of the unit to the
extent that the release of hazardous or flammable
material is possible. Example- Explosion
 Safeguards should be included whenever the team
determines that a combination of cause and
consequence presents a credible process hazard
1. Those systems, engineered designs and written
procedures that are designed to prevent a catastrophic
release of hazardous or flammable material.
Example- Pressure Relief Value
2. Those systems that are designed to detect and give
early warning following the initiating cause of a
release of hazardous or flammable material.
Example- Pressure level Indicator
3. Those systems or written procedures that mitigate the
consequences of a release of hazardous or flammable
material. Example- Deliberate Ignition
 RECOMMENDATIONS
Recommendations are made when the safeguards for a
given hazard scenario, as judged by an assessment of the
risk of the scenario, are inadequate to protect against the
hazard.

1. High priority action items should be resolved within 4

months.
2. Medium priority action items should be resolved within
4-6 months.
3. Lower priority action items should be resolved
following medium priority items.
Prerequisites
As a basis for the HAZOP study the following information should
be available:

Process flow diagrams (PFD)

Piping and instrumentation diagrams (P&IDs)
Layout diagrams
Material safety data sheets
Provisional operating instructions
Heat and material balances
Equipment data sheets Start-up and emergency shut-down
procedures
HAZOP PROCEDURE
1. Divide the system into sections (i.e., reactor, storage)
2. Choose a study node (i.e., line, vessel, pump, operating
instruction)
3. Describe the design intent
4. Select a process parameter
5. Apply a guide-word
6. Determine cause(s)
7. Evaluate consequences/problems
8. Recommend action: What? When? Who?
9. Record information
10. Repeat procedure (from step 2)
 Consider, as a simple example, the continuous
process shown in Figure. In this process, the
phosphoric acid and ammonia are mixed, and a
non-hazardous product, diammonium
phosphate (DAP), results if the reaction of
ammonia is complete. If too little phosphoric
acid is added, the reaction is incomplete, and
ammonia is produced. Too little ammonia
available to the reactor results in a safe but
undesirable product. The Hazop team is
assigned to investigate "Personnel Hazards from
the Reaction".
CONTINUOUS PROCESS EXAMPLE FOR HAZOP TECHNIQUE
 Node:1 Process parameter: flow
Intention:-Phosphoric acid feed solution to the reactor at a rate of 1000 lpm
and 3 bar Pressure
Guide Deviation Causes Consequences Action
Word Required
 Node:1 Process parameter: flow
Intention:-Phosphoric acid feed solution to the reactor at a rate of X gpm
and Y psig
Guide Deviation Causes Consequences Action
Word Required

No No Flow Valve A Falls Excess Automati

At Study Closed Ammonia In c Closure
Node 1 Reactor And Of Valve
Phosphoric Release To B On Loss
Acid Supply Work Area Of Flow
Exhausted From
Phosphor
ic Acid
Plug In Pipe, Supply.
Pipe Ruptures

More Increased Flow Excess Phosphoric

At Study Node Acid Degrades
1 ---- Product But -----
Presents No Hazard
To Workplace.
Less Reduced Flow Valve A Partially Closed Excess Ammonia In Automatic
At Source Reactor And Release Closure Of
Guide Deviation Causes Consequences Action
Word Required

Part Of Decreased Vendor Delivers Wrong Excess Ammonia Add Check Of

Concentrati Material Or Concentration In Reactor And Phosphoric Acid
on Of Release To Work Supply Tank
Phosphoric Error In Charging Phosphoric Area. Amount Concentration
Acid At Acid Supply Tank Released Is After Charging
Study Node Related To Procedures
1 Quantitative
Reduction In
Supply. Team
Member Assigned
To Calculate
Toxicity Level
Versus Flow
Reduction
Reverse Reverse No Reasonable Mechanism For
Flow At Reverse Flow. ----- -----
Study Node
1
Other Material Wrong Delivery From Vendor Depends On Plant Procedures
Than Other Than Wrong Material Chosen From Substitution; Team To Provide Check
Phosphoric Plant Warehouse Member Assigned On Material
Acid In Line To Test Potential Chosen Before
A Substitutions Charging
Based On Phosphoric Acid
Availability Of Supply Tank.
Other Materials At
Site And Similarity
In Appearance
Node:2 Process parameter: flow
Intention:-Deliver 20% ammonia solution to the reactor
at Y gpm and Z psig
Guide Deviation Causes Consequences Action required
word
High High flow at Ammonia feed line Untreated Consider adding an
study node 2 control valve B fails ammonia solution alarm/shutdown of the
to open. carry over to the system for high ammonia
Operator sets DAP storage tank solution flow to the
ammonia flow rate and release to the reactor.
too high. work area. Ensure periodic
maintenance and
inspection for valve B is
adequate.
No Leakage at Corrosion Small, continuous Ensure adequate
flow ammonia erosion leak of ammonia ventilation exists for
tank external impacts to the enclosed enclosed work area.
Gasket and packing work area
failures
Maintenance errors
Node:3 Process parameter: flow
Intention:-Deliver product flow to the storage tank at X
gpm and Y psig.

Guide Deviation Causes Consequences Action

word required

Reverse reverse flow at no reasonable

study node 1 mechanism for ----- -----
reverse flow.
Advantages
Systematic examination
Multidisciplinary study

Utilizes operational experience

Covers safety as well as operational aspects

Solutions to the problems identified may be indicated

Considers operational procedures

Covers human errors

Study led by independent person

Disadvantages
Can be time-consuming
Relies on having right people in the room
Finally...,
HAZOP is an essential tool for hazard
identification and have been used successfully to
improve the safety and operability of both new and
existing chemical plant. The technique is not confined
to the chemical and pharmaceutical industries and
has also been used successfully in a number of other
industries, including the off-shore oil and food
industries.
WHAT IF ANALYSIS
 WHAT-IF ANALYSIS
A What-If is a brainstorming approach in which a
group of people familiar with the process ask questions
about possible deviations or failures and what things can
go wrong
Each question represents a potential failure in the
facility or mis-operation of the facility.
Lead by an energetic and focused facilitator, each
member of the review team participates in assessing
what can go wrong based on their past experiences and
knowledge of similar situations
At each step in the procedure or process, What-If
questions are asked and answers generated.
What-If Analysis Steps
1. Divide the system up into smaller, logical subsystems
2. Identify a list of questions for a subsystem
3. Select a question
4. Identify hazards, consequences, severity, likelihood,
and recommendations
5. Repeat Step 2 through 4 until complete

.What-If analysis are intended to identify hazards,

hazardous situations, or accident scenarios.
.For a small or simple system a What-If analysis will
take 4 to 8 hours to prepare, 1 to 3 days to evaluate the
process, and 1 to 2 days to document the results.
. For larger or more complex processes, it will take 1 to 3
days to prepare, 4 to 7 days to evaluate, and 4 to 7 days
to document.
 WHAT-IF QUESTION EXAMPLE
Equipment failures What if a valve leaks?.
Human error What if operator fails to restart pump?

External events What if a very hard freeze persists?

Team members usually include

Operators

Maintenance personnel,

Design engineers, chemist, structural engineer, radiation

expert,
A safety representative will lead the team. Their
knowledge of design standards, regulatory codes, past and
potential operational errors as well as maintenance
difficulties brings a practical reality to the review
Advantages of What if? analysis
Easy to apply.

Disadvantages of What if? analysis

Experienced assessors are required . Their
thoroughness and accuracy are dependent upon
the composition and expertise of the team
performing the analysis.
Hazards can be missed

Time consuming for complex processes.

What If hazard analyses stops at a single point of

failure and does not investigate the system further.
(i.e., This method would not evaluate a series of
failures and the potential consequence of this
series.)
CHECKLIST ANALYSIS
 CHECKLIST

Consists of using a detailed list of prepared

questions about the design and operation of the
facility
Questions are usually answered Yes or No
Used to identify common hazards through
compliance with established practices and
standards.
Checklist analysis involve assessment using
predefined checklists. They are used in various
stages of the project life cycle like risk
identification.
A checklist intended for use during the initial design of
the process will be considerably different from a
checklist used for a process change
CHECKLIST QUESTION CATEGORIES
Causes of accidents
Process equipment
Human error
External events
Facility Functions
Alarms, construction materials, control systems, documentation and
training, instrumentation, piping, pumps, vessels, etc.
 CHECKLIST SUMMARY
The simplest of hazard analyses
Easy-to-use
Provides quick results; communicates information well
Effective way to account for lessons learned
Not helpful in identifying new or unrecognized hazards.

Checklist should be prepared by experienced engineers

Its application requires knowledge of the system/facility and

its standard operating procedures
Checklist Should be audited and updated regularly
 CHECKLIST TASK
Your University has many Gas cylinders materials Create a
checklist for the Handling, storage, maintenance and use of
Gas cylinders.
SAFETY REVIEW
SAFETY REVIEWS
Method that is commonly used to identify safety
problems in laboratory and process areas and to develop
solutions is the safety review.
There are two types of safety reviews
Informal and

Formal.
INFORMAL SAFETY REVIEW
The informal safety review is used for small changes
to existing processes. The reviewers simply meet in
an informal fashion to examine the process
equipment and operating procedures and to
offer suggestions on how the safety of the
process might be improved.
Significant improvements should be summarized in a
memo for others to reference in the future. The
improvements must be implemented before the
process is operated.
The informal safety review procedure usually involves
just two or three people. It includes the individual
responsible for the process and one or two others not
directly associated with the process but experienced
with proper safety procedures.
FORMAL SAFETY REVIEW
The formal safety review is used for
New processes,

Substantial changes in existing processes,

Processes that need an updated review.

The formal safety review is a three-step process.

1. Preparing a detailed formal safety review
report,
2.Committee reviews the report and inspect the
process, and
3. Implementing the recommendations.
 Event tree Analysis
Event tree analysisis based on binary logic, in
which an event either has or has not happened or
a component has or has not failed. It is valuable in
analyzing the consequences arising from a failure
or undesired event.It is a forward bottomup
approach.

An event tree begins with an initiating event, such

as a Loss of Containment, Loss increase in
temperature/pressure, Fire, Explosion or a
release of a hazardous substance. The
consequences of the event are followed through a
series of possible paths.
 Why event tree analysis is
required
When an accident or process
deviation (i.e. an event) occurs in a
plant, various safety systems (both
mechanical and human) come into play
to prevent the accident from
propagating. These safety systems either
fail or succeed.
 Definition
Initiating event - Failure or undesired event that initiates the start
of an accident sequence.
Example- Fire, Explosion or a release of a hazardous
substance

Pivotal events- Intermediary events between the Initiating Events

and the final mishap. These are the failure/success events of the
design safety methods established to prevent the Initiating Event
from resulting in a mishap.
Example- Fire alarm system, Sprinkler system, Fire detection
system

Accident scenario - Series of events that ultimately result in an

accident. The sequence of events begins with an initiating event and
is (usually) followed by one or more pivotal events that lead to the
undesired end state.
The diagram shows an initiating event (e.g. fire) and the
subsequent operation or failure of three systems (Fire
Detection, Alarm system and sprinkler system) which
would normally operate when the fire occur. The
initiating event is typically specified as an expected
annual frequency (e.g. 2 times per year) and the
success/failure for each system as a probability.
Event tree Analysis- Fire in a room
 Steps in Event tree construction

1. Identify the Initiating event

2. Identify the controls that are assigned to
deal with the primary event such as
automatic safety systems, alarms on
operator actions.
3. Construct the event tree beginning with the
initiating event and proceeding through
failures of the safety functions.
4. Establish the resulting accident sequences.
5. Identify the critical failures that need to be
addressed
Event tree PLG Leak from storage tank
Advantages
Combines hardware, software,
environment, and human interaction.
Permits probability assessment.
Commercial software is available.

Disadvantages
An ETA can only have one initiating event,
therefore multiple ETAs will be required to
evaluate the consequence of multiple
initiating events.
Requires an analyst with some training
and practical experience.
Event tree Fire in a conveyor system
Top Event

Intermediat
e Event

Basic
Event
Fault tree Analysis
Motor does not run when switch is pressed
 Fault Tree Analysis
Fault tree analysis (FTA) is a top-down
approach to failure analysis, starting with
a potential undesirable event (accident)
called a TOP event, and then determining
all the ways it can happen.

The analysis proceeds by determining

how the Top event can be caused by
individual or combined lower level
failures or events.
 Fault tree analysis
1. An undesired event is defined
2. The event is resolved into its immediate
causes
3. This resolution of events continues until
basic causes are identified
4. A logical diagram called a fault tree is
constructed showing the logical event
relationships
. Fault trees originated in the aerospace industry
and have been used extensively by the nuclear
power industry to qualify and quantify the
hazards and risks associated with nuclear power
plants.
 Gate Symbols

OR gate - the output occurs if any input occurs

AND gate - the output occurs only if all inputs occur (inputs are
independent)
Exclusive OR gate - the output occurs if exactly one input occurs
Priority AND gate - the output occurs if the inputs occur in a specific
sequence specified by a conditioning event
Relationship between Fault Trees and
Event Trees
Event trees begin with an initiating
event and work toward the
consequences (induction).
Fault trees begin with a top event
and work backward toward the Basic
causes (deduction).
FMEA (FAILURE MODE EFFECT ANALYSIS)
 History of FMEA
First used in the 1960s in the Aerospace
industry during the Apollo missions
In the late 1970s, the automotive industry
was driven by liability costs to use FMEA
Later, the automotive industry saw the
advantages of using this tool to reduce
risks related to poor quality
 FMEA TERMS
Failure mode - the way in which
something might fail

Effects analysis studying the

consequences of the various failure
modes to determine their severity to
the customer.
 What is FMEA?
Failure modes and effects analysis (FMEA) is a
step-by-step approach for identifying all possible
failures in a design, a manufacturing or assembly
process, or a product or service.

OR

Failure Modes and Effects Analysis (FMEA) is a

qualitative, systematic and highly structured
technique that is used to investigate how a
system or system components can result in
performance problems.
 Process Steps

FMEA Procedure
1. For each process input (start with high value
inputs), determine the ways in which the input
can go wrong (failure mode)
2. For each failure mode, determine effects
Select a severity level for each effect
3. Identify potential causes of each failure mode
Select an occurrence level for each cause
4. List current controls for each cause
Select a detection level for each cause

98
 Process Steps

FMEA Procedure (Cont.)

5. Calculate the Risk Priority Number (RPN)
6. Develop recommended actions, assign
responsible persons, and take actions
Give priority to high RPNs
MUST look at severities rated a 10
7. Assign the predicted severity, occurrence, and
detection levels and compare RPNs

99
 FMEA Form (Template)

Identify failure modes Determine and assess

Identify causes of the Prioritize
and their effects actions
failure modes
and controls
 Failure Specific Cause Effect of Failure Likeliness Detectability Severity of Risk

FMEA
Mode
Gas will not
Spring broke Explosion resulting in
of Failure
3
of Failure
5
Failure Priority
10 150
shut off preventing valve property damage
from closing and/or serious injury

Likeliness of Failure: 1-10 with 10 representing most likely

Detectability of Failure: 1-10 with 10 representing most difficult
Severity of Failure: 1-10 with 10 representing most severe
Risk Priority = (Likeliness of Failure) X (Detectability of Failure) X
(Severity of Failure)

101
FMEA INPUTS AND OUTPUTS

Inputs Outputs
Brainstorming List of actions to prevent
C&E Matrix causes or detect failure
Process Map modes
Process History
Procedures
FMEA
History of actions taken
Knowledge
Experience
Likelihood of Occurrence Rank List
Rank of Likelihood of Description
Occurrence
1 Never Happened

2-3 1 in 365 days

4-5 1 in 220 days

6-7 1 in 180 days

8-9 1 in 100 days

10 <30 days
Severity Rank List (Failures)
Rank of Description
Severity
1 Failure would not be noticed

2-3 Failure causes in nuisances but no

performance losses
4-5 System under minor performance losses

6-7 System Inoperable or Unserviceable

8-9 Partial Breakdown of the system. System

can be repaired

10 Complete Breakdown of the system

 Detection Rank List
Rank of Description
Detection
1 Online Detection & Automatic Response
System
2-4 Online Detection & Manual Response
System

5-6 Periodic Physical/ Manual Detection &

Manual Response System

7-8 Random Physical/ Manual Detection &

Manual Response System

9-10 No Detection & Manual System

 Calculating a
Composite
Score

Risk Priority Number (RPN)

Risk Priority Number (RPN): The failure modes risk is found by the
formula RPN = S x O x D.
RPN = Severity x Probability of Occurrence x Probability of
Detection.
RPN will be a number between 1 (virtually no risk) and 1000
(extreme risk).

Severity X Occurrence X Detection = RPN

106
RISK PRIORITY NUMBER
 TYPES of FMEAs
Design
Analyzes product design before release to production,
with a focus on product function.
Analyzes systems and subsystems in early concept and
design stages.
Process
Used to analyze manufacturing and assembly processes
after they are implemented.
It is used either in the assembly or manufacturing or both.
 WHEN TO DO FMEA?
New process being designed.
New equipment developed or
purchased.
Existing process being designed or
redesigned.
To monitor and track improvement
over time.
 BENEFITS OF FMEA
Improve the quality, reliability and safety of a
product/process.
Improve company image and competitiveness.
Increase user satisfaction.
Reduce system development timing and cost.
Collect information to reduce future failures, capture
engineering knowledge.
Reduce the potential for warranty concerns.
Early identification and elimination of potential failure modes
Emphasize problem prevention.
Minimize late changes and associated cost.
Catalyst for teamwork and idea exchange between functions.
Reduce the possibility of same kind of failure in future.
Reduce impact of profit margin company.
Reduce possible scrap in production.
 LIMITATIONS OF FMEA
Employee training requirements
Initial impact on product and manufacturing
schedules.
Financial impact required to upgrade design,
manufacturing, and process equipment and tools.
 BOW TIE ANALYSIS
By linking Hazards & Consequences to an Event it is possible to
develop the relationship to include the causes, or Threats, and the
Prevention & Recovery Measures
There is only an event when humans come into contact with a hazard.
But there are many ways this contact can be prevented. Organisational
barriers such as permits and Safe working procedures and standards.
Leaders and supervisors who provide guidance and ensure procedures are
followed
The problem is that none of these barriers is 100 percent safe, all of them
have holes big or small
The holes all line up and at this point there is an event sometimes causing
an injury.
However as long as one barrier is working effectively, even when the others
fail an individual will be protected (it will be a near miss)
SWISS CHESSE MODEL
http://
www.cgerisk.com/knowledge-base/risk-assessment/escalation-factors
http://www.risktec.co.uk/software.aspx
BOW TIE DIAGRAM
Bowtie diagram is an integration of Fault Tree and Event
Tree put togetherA Bow-tie diagram consists of 3-parts as
under:
i. Left side is a Fault Tree showing Causes leading to an
Event,
ii. At the centre of the bow-tie diagram is the event we
dont want to happen,
iii. The right side of a Bowtie contains details of the
potential consequences and the mitigating controls (the
event tree).