June 18, 2024
DFSR: Mistake Proofing Electrical Inspections
To minimize risk to thermographers, facilities are increasingly using Design for Safety and Reliability (DFSR) strategies to eliminate human error. The concept of DFSR involves engineering and invention to circumvent the conditions that would allow mistakes to happen.
Performing infrared thermography inspections on live electrical equipment is potentially dangerous. For proper readings to be taken, the equipment must remain energized while it is being scanned. It’s impossible to get a reading through a metal panel, so it’s up to the thermographer to do whatever is necessary to get a clear line of sight of the interior components of the electrical equipment.
This used to mean removing the front panel of the equipment, revealing the live components within. This method is potentially dangerous because it exposes the thermographer to live electrical components, putting them at risk of electrocution. With an open panel, you are within inches of serious injury.
Everyone makes mistakes. Whether the thermographer is young and inexperienced or a seasoned professional, there exists a very real possibility of dropping a tool or inching too close to the live components.
There are risks beyond human error, too. An arc flash is a sudden release of electrical energy through the air when a high-voltage gap exists and there’s a breakdown between conductors or between conductors and ground. This event can produce intense light and heat, which can cause severe injuries or even death to anyone nearby, as well as significant damage to equipment. An arc flash can occur when front panels are removed, exposing live components.
To minimize risk to thermographers, facilities are increasingly using Design for Safety and Reliability (DFSR) strategies to eliminate human error. The concept of DFSR involves engineering and invention to circumvent the conditions that would allow mistakes to happen.
Poka-yoke, a term derived from Japanese, translates to “mistake-proofing” or “error-proofing.” This concept, rooted in the manufacturing practices of the Toyota Production System, was introduced by Shigeo Shingo in the 1960s. Poka-yoke focuses on preventing errors in manufacturing and business processes, thereby enhancing safety and operational efficiency. It emphasizes simplicity and effectiveness, often involving low-cost solutions to eliminate defects caused by human errors. This makes it a vital aspect of DFSR.
Poka-yoke solutions are often simple and effective. They do not require complex technology or significant investments but focus on smart design solutions to protect people and equipment. The primary aim of poka-yoke is to prevent errors from occurring in the first place.
In the context of electrical inspections, then, DFSR is focused on eliminating the need to remove panels altogether while still providing a clear line of sight to the components. No exposed components result in a greatly reduced opportunity for human error and arc flash, making infrared inspection IR windows a prime example of a DFSR technology.
Implementing DFSR offers numerous benefits to organizations, including:
Increased Efficiency: Error-proofing processes lead to smoother operations, reducing downtime and increasing productivity. With inspection windows, for example, there is no longer a need to remove panels and to wear bulky PPE because the risk of arc flash and electrocution is removed, reducing the overall time of the inspection.
Enhanced Safety: DFSR solutions often enhance safety by preventing accidents and injuries, particularly in industries with high-risk operations. For electrical inspections this means not removing panels from electrical equipment.
Employee Empowerment: When following an Operations Driven Safety and Reliability (ODSR) plan, DFSR solutions empower operators to perform their own inspections on equipment, minimizing risks.
DFSR is a powerful approach to error-proofing that enhances quality, efficiency, and safety in various industries. By focusing on preventing errors at the source and providing immediate feedback when errors occur, organizations can significantly reduce risks to personnel. The simplicity and cost-effectiveness of poka-yoke solutions make them accessible to businesses of all sizes, fostering a culture of continuous improvement and employee empowerment. As organizations strive for excellence in their operations, the principles of DFSR offer a practical and effective path to achieving sustainable safety and quality improvements.
