Design for Safety (DfS)
OBJECTIVES
Dramatic savings can occur through creative design practices that focus on inherent product risks very early in the design process, and on ways to minimize each risk factor. At a time when safety recalls are becoming an increasingly costly and damaging problem for companies in a variety of industries, including automotive, aerospace, production lines, and many others. This seminar reveals how significant cost savings can be obtained by designing for safety.
With a focus on writing clear, accurate safety specifications, attendees will engage in hands-on activities where they will practice balancing intuitive vs. logic-based design considerations. They will also discover risk-mitigation techniques that can be effectively implemented in their workplaces to prevent costly recalls.
Challenging the usual paradigm of “safety costs money,” this seminar also explores the creative techniques used by several famous engineering managers to increase safety and decrease costs. Other topics include accident causes and prevention, potential misuse of product, hazard analysis (including latent hazard initiation), testing, and software safety design. A copy of instructor Dev Raheja’s text Creativity: The Art of Doing Right Things Right will be provided to each participant.
WHO SHOULD ATTEND
This seminar will be especially valuable for:
- Design engineers & managers
- Research & development engineers & managers
- Safety engineers & managers
- Engineers in reliability and quality assurance
- Service engineers & managers
- Any engineer responsible for specification writing
- Any manager responsible for safety, quality or risk management
Some experience in design will be helpful but not essential
COURSE OVERVIEW
By attending this seminar, you will be able to:
- Predict potential accidents before the design is released
- Design creative solutions that reduce costs and deliver higher returns
- Write specifications that clearly define safety requirements and the desired levels of safety
- Identify potential hazards introduced in manufacturing
- Identify safety risks posed by product misuse
- Prepare risk analysis reports for managers to use in decision-making
OUTLINE
Safety in Design Concepts
- System view of safety
- Boundaries of safety
- Criteria for safety
Hands-On Workshop: Safety Boundaries
Theory of Accidents
- Domino effect
- Single causation theory
- Multiple causation theory
- Energy control theory
Writing Safety Specifications
- Holistic considerations
- Life cycle considerations
- Abuse/misuse considerations
- Robustness criteria for safety
Hands-On Workshop: Writing Safety Specifications
Writing Interface Specifications
- Hardware/software interface
- Hardware/hardware interface
- Software/software interface
- Software/human interface
- Hardware/human interface
Safety Design Process to Fine-tune Specifications
- Hazard analysis
- Identifying hazards
- Assessing the risk
- Mitigating the risk
- Cost effective control of hazards
Hands-On Workshop: Hazard Analysis
Minimizing Accidents in Early Design
- Conceptual safety analysis
- Logical solutions
- Intuitive solutions
- Innovation with high return on investment
Minimizing Accidents in Detail Design
- Subsystem hazard analysis
- Failure mode, effects, and criticality analysis for safety
- Fault tree analysis
- Operations and support hazard analysis
- Maintenance engineering hazard analysis
Hands-on Workshop: Safety Enhancement Through Fault Tree Analysis
Minimizing Accidents in Complex Systems
- Making use of lessons learned
- Design for robust human interface
- Design for robust software interface
- Design for sneak conditions
Avoiding Latent Hazard Initiation in Manufacturing
- Process safety hazard analysis
- Production qualification for safety
- Safety inputs to design
- Design for preventing defects in production
Hands-on workshop: Designing Out Latent Unsafe Events
Testing for Safety
- Prerequisites for developing tests
- Accelerated testing for safety qualification
- Safety tests in production and feedback to design
- Tests for unexpected user related failures
- Tests for rare events
Embedded Software Safety
- Software system safety concepts
- Requirements analysis for safety
- Software hazard analysis
- Identifying new requirements for safety
Software Safety Design Control Techniques
- Design control techniques
- Software preliminary hazard analysis
- Software failure mode and effects analysis
- Selecting structure for safety
- Selecting architecture for safety
