What do you do if your Engineering Design decision leads to potential risks?

Once the design is completed it is mandatory to review internally from all aspects and any potential risk should be identified here. Once risk is identified involve stake holders & SMEs to do a root cause analysis and find a solution to mitigate the risk without compromising much on cost & schedule.

Once risks have been identified, engineers should assess their likelihood and potential impact on the project or work daily activities

I do find very positive to identify risks at Engineering Design stage. It’s at first a sign of a level of check and balance as well as quality process. Furthermore, I’d rather identify a risk and manage it at this stage rather than at cutover or later when it might be too late. when risk is found, the very first step is to analyze it and understand the two elements ; impact and likelihood. A qualitative and then Quantitative Risk Assessments shall be considered based on risk levels so as to establish how to eliminate risks or bring it down to ALARP. Ideally, engineering designs shall inherently address risks, however this is not always feasible hence a risk based approach shall be followed with no compromises on process & individual safety.

Once the risks are identified, mitigation to be added for time and schedule impact. The identified risks are to be disseminated to all the stake holders to avoid last minute surprise.

Every company have different risk management and risk matrix. Risk can be classified into safety risk , Environmental risk or Commercial risk. Need to rank what is the risk based on risk matrix. Based on hazard mitigation hierarchy which consist of elimination, substitution, engineering control, administrative control and weakest part is PPE. Best effort is possibility to eliminate Hazard or substitute the hazard. If not possible to eliminate or substitute hazard then engineering control. HAZOP study is conducted as Hazard identification and continue with LOPA that have recommendation on what safety integrity level (SIL) to be installed to prevent Loss of Primary Containment (LOPC) and what is RRF (Risk Reduction Factor) based on design.

Hazards frequently appear on projects during all phases of development, from initial design, through detail design, construction, and commissioning. The best way to identify potential hazards and develop controls to mitigate them is through collaboration with the team. Peer review with representatives from all aspects of the project's development including engineering, manufacturing, service, and sales will lead to a more comprehensive hazard assessment and having a collaborative base of ideas to solve the issues can often lead to solutions which are simpler or cheaper to implement than if only engineers design the solution. Listening to the expert trades people is essential in all phases of product development.

One mitigation strategy that is easy to overlook is to improve detectability of the failure mode that is in play. If repairs are inexpensive related to the capital investment needed to eliminate the risk, and the failure can be tolerated with respect to impact on the bottom line, consider trading in that upgraded material, that extra pump or valve, or that enhanced level of quality for a robust monitoring plan with a written alarm response procedure.

Design decision implemented for installation and execution requires first a OPN risk analysis and consequence analysis. This shall be tested by start up trial. Experienced operator shall be embedded in the project who shall analyze this with JSA. In case there is negative consequences, SRN or OPN DCN shall be countered to Engineering for value analysis, technical reassessment and cost implications assessment. This can be useful to negate long term effect.

After assessing the risk, you'll need to develop a mitigation plan. This plan should outline specific steps to reduce the risk to an acceptable level. You might need to redesign certain components, implement additional safety features, or even alter the project scope. Collaboration with your team is vital here, as different perspectives can lead to innovative solutions. Remember, the goal is to find a balance that maintains design integrity while ensuring safety and compliance

Collaboration with your team is vital here, as different perspectives can lead to innovative solutions. This could involve engaging with mechanical engineers to reinforce structural components, consulting with safety experts to introduce additional fail-safes, or working with project managers to adjust timelines and budgets accordingly. The goal is to find a balance that maintains design integrity while ensuring safety and compliance. Documenting the mitigation strategies and the rationale behind them is essential for future reference and to ensure that all stakeholders are informed and aligned.

In our company, risk assesment team hold regularly meetings with all engineering disciplines to clarify and scrutinize all available risks. After that engineering team with their management shall accurately assess these risks and specify the levels and complete risk forms. This way help us to know what do you need to do. I thinks this is first step for strategy.

Before the start of the project I would study and identify the potential issues and methods of solution. I would communicate the potential issues not only to the peoples in management level but also to the workers in the shop floor by having short, brief and clear communication and direction of preventing the occurrence.

Whenever working on project execution in process industry with hazards associated with it- Accuracy and Perfection can never be compromised. This level of accuracy cannot be person dependent but team dependent. Every team player shall be empowered to the level that they communicate and question without hesitation, if there is anything that appears inappropriate. Intra & inter disciplinary interactions shall flow seamlessly with no hesitation in questioning your peer or senior. For this, all team leads shall be receptive to such questions and avoid taking it on their ego but as positive feedback which will add value to their. This also imbibe sense of ownership and accountability to each team player & everyone involved strive for perfection.

Without good and effective communication plan the project could be failed to accomplished. A good project manager should handle all the information which should be delivered to the project stakeholders, and follow up the response of these stakeholders.

Consultation: Seek input from relevant stakeholders, including other engineers, subject matter experts, regulators, and project stakeholders. Collaborative problem-solving can lead to more effective solutions and ensure that all perspectives are considered. Documentation: Document all aspects of the issue, including the analysis, mitigation strategies, and any decisions made. This documentation is essential for accountability, transparency, and future reference.

Conduct rigorous testing and validation procedures to verify the performance of the design under various conditions. This includes simulated testing in controlled environments as well as field testing to evaluate real-world performance.

Testing and Validation: Thoroughly test the revised design or mitigation measures through simulations, prototypes, or other appropriate methods. Validate that the changes effectively address the identified risks without introducing new problems. Continual Monitoring: Establish a system for ongoing monitoring and review of the design to identify any new risks or unexpected consequences. Regularly reassess the project's status and make adjustments as necessary.

Communication: Communicate openly and transparently with all relevant parties about the situation, the actions being taken, and any potential implications. Clear communication fosters trust and ensures that everyone is informed and involved in the resolution process. Continuous Improvement: Use the experience as a learning opportunity to improve future design processes. Consider whether there are systemic issues within the organization or broader industry trends that need to be addressed to prevent similar incidents from occurring in the future. By following these steps, you can effectively manage and mitigate the risks associated with engineering design decisions, ensuring the safety, reliability, and success of the project.

Based on the analysis and stakeholder input, develop a comprehensive risk mitigation plan. This As per my view based on the analysis and stakeholder input, develop a comprehensive risk mitigation plan. This plan should outline specific steps and measures to address the identified risks and minimize their impact. Consider both short-term and long-term solutions

With a mitigation plan in place and stakeholders informed, it's time to implement the solutions. This phase involves revising design documents, procuring new materials, or applying alternative engineering methods as outlined in your mitigation plan. It's crucial to monitor the implementation closely to ensure that it proceeds according to plan and that the risk is effectively managed. Regular checkpoints and quality assurance measures should be in place to verify that all changes are integrated smoothly and meet safety standards.

Regular checkpoints, performance evaluations, and stakeholder feedback are integral to maintaining a vigilant monitoring process. Documenting these reviews and their outcomes helps in refining future risk management strategies and contributes to ongoing project improvement. Monitoring and reviewing should be ongoing throughout the project lifecycle, demonstrating your commitment to delivering a safe and successful outcome while adhering to project timelines and objectives.

Revisit the design to see if there are alternative solutions that can mitigate the risks without compromising the functionality or efficiency.

Implementation of the plan and insure to apply is important, but the more importance is the adoption of this plan based on actual situation. The risk assessment is an expectation based on old knowledge or whatever, but the review and adoption of mitigation plan is based on our responses to the risk if happening. Accordingly if our actions not adopted to the actual case and scenario, it may lead to more risks.

I will see design where be risk ,i will do our work we cannot do lift risks, i start to work before i check all issues and and will try to leave issues on design before start work ,

In order to make progress, we must document our lessons and learnings for future reference. This is absolutely essential as it helps us to hone our problem-solving skills, enabling us to find solutions more effectively and efficiently to any possible risks that may arise in our projects. However, in my personal view, the ability to learn from our mistakes, adapt to different situations and risks, and have the necessary aptitude to identify solutions are skills that can only be mastered through experience. The more experience we gain, the more we refine our skills, making us better equipped to handle any challenges that come our way.

Engineering world of design constantly evolved in this natural calamity and weather changes. To avoid errors and omissions default on the part of the designer, these considerations must be learned and adapted on every engineering design at all costs.

Throughout my career, I have run into several risk problems. With the help of my team, we have identified them and worked through the situation to the end completing the project. Throughout the whole time of the project I have been transparent with the client and informed on a timely matter. With this type of transparency, I have created a long-term relationship with clients over the years.