Enhancing Product Quality Through System Safety Engineering

In today's fast-paced development environment, ensuring the highest quality in product design is paramount. A thorough review process before modifications or construction can yield significant benefits, leading to higher quality products while reducing costs. This proactive approach serves not only as a valuable sanity check but also as a foundation for effective system safety engineering.

Key components in assessing product safety and reliability include several critical metrics. The failure effect probability (β) evaluates the likelihood that a failure will result in a specific criticality classification. Meanwhile, the failure mode ratio (α) expresses the probability of a part failing in a particular mode. Together with the part failure rate (λn) and operating time (t), these metrics help engineers gauge potential risks associated with a system's components.

To objectively measure and rank these risks, engineers employ a criticality matrix. By calculating failure mode criticality numbers (Cm) using the formula ( Ctmp = \beta \alpha \lambda ), analysts can determine an item's overall criticality number (Cr). This systematic approach allows teams to prioritize which failures could have the most significant impact on system functionality.

Real-world examples underline the importance of human factors in safety analysis. For instance, NASA's Magellan spacecraft suffered a catastrophic loss due to a technician's mistake in connecting high- and low-voltage lines. The inability to visually verify the connections led to a fire that destroyed a $400 million spacecraft. Similarly, a production facility experienced major issues when flexible piping was incorrectly routed, resulting in spilled product and significant downtime. These incidents highlight how human error can compromise even the best-designed systems.

Even everyday experiences, such as mishaps with a coffee machine, reflect the consequences of overlooked details in design and assembly. When a cup is placed at an angle, it can lead to spilled coffee instead of a satisfying drink. Such examples serve as reminders that attention to detail and systematic safety assessments are essential across all applications, from sophisticated spacecraft to simple consumer products.

Integrating systematic reviews and human factors analysis into the design process ultimately fosters a culture of safety and reliability. By emphasizing these practices, organizations can enhance their product offerings and build trust with consumers, ensuring that both quality and safety remain top priorities in their operations.