Dr. Bud Gookins was an advocate of product hazard analysis, frequently presenting on this topic at the ASQ World Conference. This article highlights some key points of product hazard analysis. 

Product safety feature analysis involves assessing the unique hazards and applications of each product. Design engineers must consider customer needs, environmental applications, design parameters, materials, potential uses, and misuse during the conceptual stage. Hazard analysis continues from concept through post-production, identifying and eliminating unsafe conditions early. 

In the pre-production stage, prototypes undergo testing to validate safety features. The conceptual design hazard analysis identifies potential hazards, safeguards, and tests for verification. Though often perceived as costly, investing time in this stage can prevent issues, reducing long-term production costs. Assigning a “Safety Engineer” ensures safety criteria are met throughout the design process. 

Following the conceptual hazard analysis, the safety engineer performs a design analysis to identify potential hazards. If a design fails to meet safety standards, it must be modified or redone. This ensures product safety in the planning phase, avoiding costly changes later. Manufacturers must verify that their products are fit through analysis and testing. Verification involves inspecting the product or its components through physical inspection, purchase material inspection, or disassembly and evaluation (D & E) at various stages. Testing validates specific parameters and may include real-time simulations or environmental conditions, such as life testing under extreme or adverse situations. 

This article briefly addresses the effective “product hazard analysis” process. Key elements include creating a “product safety council” to oversee product liability prevention and using hazard analysis tools effectively.