System Safety and Reliability


You can use the StrongWare PC Template System, with the many tools described below, to help you manage your safety and reliability programs. You can also apply it to Risk Management . Your StrongWare provides for relating your individual reports to your spreadsheet fault tree or process diagram.
The reports are set up in your StrongWare in two ways:
1. managing your overall system safety programs; and
2. database or word processor screens and reports of individual hazards.

You can set up your plans with specific tasks with your * WorkPlan You can enter key items of your project plans for with * SafePlan .

Common hazard data may be displayed and printed in:
>> SAE Failure Modes and Effects Analysis format, *FMEA;
>> NASA Hazard Report format * NASAHR;
>> USAF Hazard Report format * HazRep; and
>> USAF Hazard Report with OSHA and cost-benefit analysis* HazBen.
You can use your HazLog columnar reports to summarize by risk indices or relative cost-benefit gains.


Note: The example templates shown on this webpage are the word processing text templates that you can * Download
To view examples of database screens, click on the hotlinks for *[__] Screen.

Failure Modes and Effects Analysis, FMEA. You can use your FMEA StrongForm to record and report your data per SAE J-1739 and QS-9000 procedures, per the Automotive Industry Advisory Group. You can view an example of an FMEA screen at * FMEA Screen
Note the use of: Severity; Probability of Occurrence; Detectability; and product of these factors, RPN. "Cls" is FMEA Class. 

                                                                                                                  
  /SW\                                              POTENTIAL                                                     
                                          FAILURE MODES AND EFFECTS ANALYSIS                                       
Item/System  Autoplane AND hangar-                                                                                 
Subsystem/   garage AND persons AND                                                                                
Component:   equipment.               Responsibility: Proprietor             Prepared By: Rich  Strong             
Model Yr/Veh: Enhanced displays.      Key Date: 09/30/1994             FMEA Date (Orig.) 09/17/1994 (Rev.)09/17/1995 
Core Team: Main Plant Quality & Reliability & Safety Improvement Team.                                             
------------------------------------------------------------------------------------------------------------------ 
 Function    Potential   Potential   Sev  Potential  O   Current    Det Recommended Responsibility  Actions Sev    
 Require-     Failure    Effect(s)         Causes /  c    Design         Action(s)   Target Date   Taken    Occ  
 ments         Mode      of Failure  Cls Mechanisms  c   Controls   RPN                                    Det RPN 
------------------------------------------------------------------------------------------------------------------ 
 Vehicle     Not contain Fire         5  Sparks AND   5 Review       6  Seal         OPEN until   Simulate     5   
 stored OR   flammable   injures         HAZMAT         MSDSs/ NEC/     hazmats.     demon-       HAZMATs.     4   
 maintained  fumes AND   persons AND  6  cause fire     NFC/        150 Ground/      stration                  4   
 OR          ignition    burns           OR             operator/       vent/        verifies.                80   
 operated.   source AND  vehicle and     pollution.     service         drain/                                     
             air.        hangar-                        manuals         detect                                     
                         garage.                                        fumes/fire

NASAHR screens and reports. If you're working with NASA, you can use the NASAHR forms and reports in accordance with NASA Handbook NHB 1700.1 (V1-B), Appendix G. 

                                                                                   
  /SW\                      N A S A   H A Z A R D   R E P O R T                   
  1. DATE: 10/12/1993  2. REPORT NUMBER:  10.20  3. STATUS: open                     
  4. TITLE: Not contain flammable fumes AND ignition  source AND air.              
  5. SYSTEM: Maintenance hangar-  garage & autoplane   vehicle AND person          
  6. EFFECTIVITY: Operate/Maintain OR  Store OR Clean up.                          
  7. OPERATION PHASE: Refuel or cleaning;  container failure during motion.        
  8. HAZARD DESCRIPTION: Lightning OR sparks  AND fuel/HAZMAT leakage/ sabotage    
  9. RISK RATIONALE: Decrease probability to Unlikely. Add start; dec.life costs.  
  10. SIGNATURES:                                                                  
  A. DESIGN ENGR; __Joan Doe_______  B. SAFETY MGR; __Rich Strong_______________   
            Sign: _________________           Sign: ____________________________   
  C. INSTAL. ENGR; _Rosa Strong____  D. INSTAL. SAFETY; __Ed Strong_____________   
            Sign:  ________________           Sign: ____________________________   
  11. RISK ASSESSMENT SECTION:                                                     
  A. CAUSES: Human error while handling HAZMATs/ container failure.                
  (1) EFFECT(S): Fire/ injuries/ loss of vehicle/facility/ pollution.              
  (2) REQUIREMENT(S): Seal HAZMATs. Ground/ vent/ drain/ fume detect-suppression   
  (3) CONTROL(S): WARNING in building plans and Operating & Maintenance Manual     
  (4) VERIFICATION: Demonstrate with users - simulate HAZMATs w/ water.            
  (5/6) SEVERITY/ PROBABILITY: 1-C;  ALSO SEE B. (1/2)                             
  B. OVERALL HR RISK ASSESSMENT AND CLOSURE:                                       
    (1/2) QUAL/QUANT: Cost $50K AND delay AND stress AND time.  Occasional.        
  12. INTERFACES: Vehicle is stored OR undergoing repairs/ maintenance.            
  13. REFERENCES: Review MSDSs/ NFC/ NEC/ operating & support training.            
  14. BACKGROUND: Updated procedure                                                
  15. STATUS OF WORK: OPEN until OT&E shows acceptable risk.                       
  PREPARING ENGINEER & DATE: Rich Strong  05/27/93

If you use Microsoft Access and you prefer to enter more data in each field,
then you can use the HazRep2 database, form and report that provides more space. 

  /SW\                   SYSTEM SAFETY HAZARD REPORT                  12/16/1993 
                                                                                  
  FILENAME: HazBen    SAFETY MGR: Rich     Strong   PHONE:937-236-0361            
  ABOUT:  Updated procedure                                                       
  DATE: 1993.10.12  RECORD:  10.20 SUSPENSE DATE:1993.05.27                       
  1.SYST/SUBSYST/UNIT: Maintenance hangar-garage & autoplane vehicle AND person   
  2.COMPNT. FAIL MODE: Not contain flammable fumes AND ignition source AND air.   
  3.SUBSYST.FAIL MODE: Human error while handling HAZMATs; container fails.       
  4.SYST./COMP./PHASE: Operate/Maintain OR Store OR Clean up.                     
  5.SYSTEM EVENT/PHAS: Refuel or cleaning;  container failure during motion.      
  6.SYST.OPER.DESCRPN: Vehicle is stored or undergoing repairs/ maintenance.      
  7.HAZARD DESCRIPTN.: Lightning OR sparks AND fuel/HAZMAT leakage/ sabotage      
  8.HAZARD INDICATION: Visible/smellable leaks/fumes/ if persons present.         
  9.EFFECT OF HAZARD : Uncontrolled fire results in loss of vehicle & facility    
 10.RISK ASSESSMENT  : Cost $50K AND delay  AND stress AND time.  Occasional.     
 11.RECOMMEND ACTIONS: Seal HAZMATs.Ground/ vent/ drain/ fume detect-suppression  
 12.ACTION  EFFECTS  : Decrease probability to Unlikely. Added system cost.       
 13.REMARKS/DOCS/DIRS: Review MSDSs/ NEC/ NFC/ operator/ service manuals          
 14.ACTION STATUS    : OPEN til OT&E shows acceptable risk.                       
  5.NOTE/CAUTION/WARN: WARNING in building plans/Operating/ Maintenance Manual    
 RISK WITH HAZARD = 1-C   RISK WITH ACTION = 1-E   NET LIFE BENEFIT = 1682.00     






 Your HazMOST or HazBen databases provide for displaying hazard analyses in several ways with 
the same data for OSHA and for System Safety. 

If you use MS Access that has a 2k limit on record size, then you can use separate databases 
for Occupational Safety and Health, OSHEP, and your System Safety and Reliability, HazMOST. 

To view an example of a hazard report screen, please click on 

 * Hazard Report Screen.  

You can use your browser's BACK function to return to this page.



/SW\      H A Z a r d s  &  B E N e f i t s,  H A Z B E N,  R e c o r d         RECNO: 1

Date,Time Z: 09/17/1994,12:12 E   About: Enter same as for LaPS.                 
DB File:HAZBEN  Rec#: ap 10.0   Prev: n/a      HSS File: MINISS    CR: B3  TXT: ap10

A. SYSTEM SAFETY HAZARD ANALYSIS REPORT ( DI-SAFT-80101A para.10.2.3.b ) ====================
Start Time:     8.25  End Time:    17.75  TimeSpan:      9.50  Mishap Class: A Status: Open   
 1. System / Subsystems / Unit_: Autoplane AND hangar- garage AND persons AND equipment.     
 2. Component Failure Mode(s)__: Not contain flammable fumes AND ignition source AND air.    
 3. Subsystem Failure Mode(s)__: Human error while handling HAZMATs OR container failure     
 4. System / Component / Phase_: Operation OR Maintenance OR Storage                         
 5. System Events / Phase______: Refuelling OR cleaning                                      
 6. Operating Description _____: Vehicle stored OR maintained OR operated                    
 7. Hazard Description_________: Sparks AND HAZMAT cause fire OR pollution.                  
 8. Hazard Indications ________: IFF persons present THEN see leaks OR smell fumes.          
 9. Effects of Hazard _________: Fire injures persons AND burns vehicle   and hangar-garage.  
10. Risk Assessment ___________: Major loss OR death. Occasional probab - ility of occurrenc 
11. Recommended Action(s)______: Seal HAZMATs.Ground / vent / drain / detect fumes / fire.   
12. Effect of Recomm. Action(s): Decrease probability to rare. Lower Life Cycle Cost.        
13. Remarks / Docs / Directives: Review MSDSs / NEC / NFC / operator / service manuals       
14. Status of Recomm. Action(s): OPEN until demonstration verifies.                          
15. Notes / Cautions / Warnings: WARNING labels on HAZMATs AND storage cabinets.              
RI-Hazard: 1A RI-Action: 1D  1A:1  1B:0  1C:0  2A:0  2B:0  3A:0  1D:0  2C:0  2D:0  3B:0  3C:0 

Fail Rate:  .2E-11  MTBF:  .40E+6  Reliability:  .90E+0  Confidence%: 95  Availability%: 88.9

Accel:  1.0 Environ: dusty Noise: 77  Pressure: .30E+7 Temp: 212  Volts: .12E+2 Amps: .99E+3
FreqMax:  .20E+0  FreqMin:  .55E+3  Rads:  .00E+0  Radiation Type: Radio  E.R.P.:  .20E+4

B. OSHA MATERIAL SAFETY DATA 29 CFR 1910.1200 and HEALTH HAZARD ANALYSIS (DI-SAFT-80106A) ===
1. Material: HAZMAT A                  NIIN : 999999      MSDS #: 9999      CAS#: 99-999     
Manufacturer: ABC MFG.                Part #: 999-9999      Telephone: 999-999-9999     
OSHA PEL:   99  ACGIH TLV: 99    Physical Form: LIQUID  Carcinogen Reference: NTP 
2. BoilPt: 555  VapDen: 5.5 VapPres: 5    WtrSol:  5.0 SpGr: 1  Evap:   0 Meth:    WtrReact:0
3. FireExt: A LEL:  4 UEL:  9  Flash Point: 666   Method:     AutoIgnition Temperature: 777 
Explos.Class:   Type:   Life Exp: 1996/04/11  Weight:  .10E+4 Ga/Cal: 0.000  Velo: 0
4. Reactivity: y  pH: 5.5  Incompatibility: Avoid oxidizers               
Decompos.Prod: Soot, CO, CO2                   Haz.Polymers: n/a                           
5. Hazard: SEPSIS   Route: EATING   Organ: STOMACH  Train: Demo      Exam: ANNUAL    
Expos: Amt;  .1E-8 Freq; 9   Dur;  3.00 Sympt: chestpan MedAggr: pleurosy FirstAid: wash,CPR
6. PPE: RESP,faceshd Ventilation: local     Hygiene: soap/wat
7. NFPA Class: 4    Disposal Process: Incinerator           
Handling Precautions: Store cool / ventilated         Other: n/a                           

C. ENVIRONMENTAL PROTECTION DATA 40 CFR 621/624 AND SARA DATA ===============================
Facility ID: XYZ Bldg 13        Quantity:  .40E+5  Number ofItems:  55  Usage:  .40E+9 
Disposal Org: EDC          Permit: 999    Location/PtSource: HazWaste Site 4     Richter: 1.0
Alt./ El./ Depth: 456   GeoCoordinates: N-S;   45.4 E-W;   78.9 Precipitation: 33 Beaufort: 0
Requisition Document #: abc         EPA Waste #: abc123      Disposal Manifest #: 123abc    
DoT Name(s): hydrocarbon fuel      DoT Class: tbd  Temporary Storage Start Date: 09/09/1995
Gen'r.Name: Dick         Strong       Tel: 800-COSMIC0      Org.Address: Safety Analysis     
Emergency Telephone: 513-236-0361          Date Shipped: 02/03/1996  EPA CODE:     

D. EVALUATION AND DECISION-MAKING WITH MOST (Item A. 11. above.)=============================
Period(1QYDC): Y Ops/Per:  1000  Life~Per: 16.09  Invest Rate:  0.040  Borrow Rate:  0.160
Units: 94USK$                DESIRED + HAZARD         ACTION +  EFFECT + STARTUP   PAYMENT   
P - Probability / Period_:   0.9000    0.1000        0.0600    0.0200    1.2500   Total 
M - Money Expenses_______:  -400.00   -100.00       -100.00      0.00   -120.00   Startup:
O - Opernl.Effect/ Output:   868.00      0.00         83.00      9.00      0.00   -250.00
S - Safety/ Enviro/ Insur:   -50.00   -900.00        -10.00   -400.00    -20.00  
T - Time/Schedule/Opporty:   -25.00     -1.00        -15.00     -1.00    -10.00   Startup
F - Spec.Fact.Security   :    10.00    -82.00         10.00      0.00    -20.00   Periodic
Q - Qual.Met. Peace Mind :     0.00    -10.00         10.00      0.00    -30.00   Payment:- 
PPV;Probable Period Value:   362.70   -109.30         -1.32     -7.84              -44.10

Compare Hazard vs. Action:    253.40 < VS. >   317.50 =>    64.10 Avoid     Break Even: -1.69

PFV; Prob. Future Values :   5,530 < VS. >   6,929 =>    1,399 Gain             Ratio:   1.25- 

PPP;Power: Desired: 6480.00  Hazard:  -99.00  Action:  540.00  Effect:    0.00  Gain:  638.92

E. CONTACT: Dick         Strong            Tel: 800-COSMIC-0     EMAIL: 800-COSMIC-0        
Remarks: SI units.

Note: HazRep provides for OLE fields:

OLE BMP: (Copy / Paste )             OLE Spreadsheet: ( Copy / Paste or Insert as Icon )
+-------------------------------+    +------------------------------------------------+
|                               |    |                                                |
|                               |    |                                                |
|                               |    |                                                |
|                               |    |                                                |
+-------------------------------+    +------------------------------------------------+


You can also use the Job Safety Analysis in spreadsheet format for reports:

SW          JOB SAFETY ANALYSIS      04/07/1998    Page:  1

RECNBR:   Sequence of Steps    Potential Hazard     Recommended Action
============================================================================
HM000001  Vehicle stored OR    Sparks AND HAZMAT    Seal HAZMATs. Ground/ 
          maintained OR        cause fire OR        vent/ drain/ detect 
          operated.            pollution.           fumes/ fire.

You can also create your fault trees as shown in * Modeling by building up from the *100.* worksheets and translating objects from your database records with FaultSS, MicroSS, MidiSS, or MiniSS translators. You can read the procedure at *Modeling

Risk Management

Managers use many ways to cover risks, so your Strongware provides ways to handle some of them. So far, management problems and safety risks have been discussed as decisions for actions. Oftentimes, due to the simple fact that all problems are not solvable, managers use risk management techniques.

  1. a. Insurance. If you consider risk management as involving insurance, for instance, you can break it down into several phases, such as assessment, purchase, and recovery, and the various financial factors, such as:
    • 1. the cost of premiums;
    • 2. what is covered, that is, how much the insurance company will pay;
    • 3. what is not covered ( the uninsured or self-insured parts);
    • 4. the cost of the deductible part of the coverage;
    • 5. the sacrifice cost of the premiums and the uninsured risk; and
    • 6. the increases in premiums in the event of a covered risk.
  2. b. Using MOST for decisions. In the risk assessment and purchase phases, you can determine the relative costs and benefits of fixing versus self-insuring with investment versus purchase of insurance. You can consider risk management in your decision-making by using the factors in the 'CON' or 'EFFECT' columns for your LaPS or HazMOST decision-making. Notice how the six factors fit into the MOST:
    • Note. Probability of the event is "1" for the time period and task being considered.
    • 1. Money Cost is 1. above, cost of premiums;
    • 2. Operational Effect is 2. above, covered risk;
    • 3. Safety is 3. above, uncovered risk;
    • 4. Time/ Opportunity is 4. above, deductible cost;
    • 5. Special Factor is 5. above, sacrifice cost; and
    • 6. Quality Metric is 6. above, increased premiums.
    If you use this method, you can determine the better mix of self-insuring and purchasing insurance, depending on the mix of investments, other capital, and credit that you have available to cover self-insuring.

You can transfer your system data to your spreadsheet fault trees, process safety diagrams, and system models. Computerized Operational System Models of Integrated Control are called by the acronym COSMIC.
If you like integrated safety and total quality management, then you can download an MS Word 6 journal article,
* COSMIC (246k)
You can click on any of the links below for more information.

The official Air Force guidance for System Safety may be seen at:
* USAF System Safety .
When you view the page, you can click on the links to MIL-STD-882C and CHANGE 1, then review the various tasks.

If you are using Microsoft Word and you're working to DOD requirements or for a self-audit, then you can use a Safety Assessment Report template, * SAR .

You can download a copy of the Safety Analysis Systems logo at swlogo and use it freely.

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