How can you manage risks in industrial automation?

Industrial automation can improve productivity, quality, and safety in plant engineering, but it also comes with potential risks. These risks can affect the performance, reliability, and security of the automated systems, as well as the health and well-being of the workers and the environment. Therefore, it is essential to identify, assess, and manage these risks effectively. In this article, you will learn some of the common risks in industrial automation and how to mitigate them.

1 Risk identification

The first step in managing risks in industrial automation is to identify them. This involves collecting and analyzing information about the automated systems, the processes, the hazards, and the stakeholders. You can use various methods and tools to identify risks, such as checklists, surveys, interviews, inspections, audits, tests, simulations, and scenarios. The goal is to have a comprehensive and accurate picture of the potential sources, causes, and consequences of risks in industrial automation.

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Yasir Ahmed, CMIOSH IdipNEBOSH

Lead HSE Engineer at Al Muftah Group | 11+ years | B.Tech (Engineer) | CMIOSH | IdipNEBOSH | Specialized in Oil and Gas Processes
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Managing risks in industrial automation is crucial to ensure the safety, reliability, and efficiency of automated systems. Here are some key strategies to manage risks in industrial automation: 1. **Risk Assessment:** - Conduct a thorough risk assessment before implementing any automation system. Identify potential hazards, failure modes, and consequences. - Use tools like Failure Modes and Effects Analysis (FMEA) to systematically evaluate and prioritize risks. 2. **Safety Standards and Regulations:** - Adhere to relevant safety standards and regulations specific to the industry and location. For example, ISO 13849 for machinery safety or IEC 61508.

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2 Risk assessment

The next step is to assess the risks based on their likelihood and impact. This helps you to prioritize the risks and allocate resources accordingly. You can use qualitative or quantitative methods to assess risks, depending on the availability and quality of data, the complexity of the systems, and the level of detail required. Some of the common methods and tools for risk assessment are risk matrices, risk registers, risk maps, risk indicators, and risk models.

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3 Risk mitigation

The third step is to mitigate the risks by implementing appropriate measures to reduce or eliminate them. These measures can be preventive, corrective, or adaptive, depending on the nature and timing of the risks. You can use various strategies and techniques to mitigate risks, such as design, engineering, installation, operation, maintenance, monitoring, control, training, communication, and documentation. The goal is to enhance the efficiency, effectiveness, and resilience of the automated systems.

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Muhammad Mujtaba

Health Safety and Environment Practionier | ISO IMS Lead Auditor (OHS , EHS & QMS)| NEBOSH IGC | OSHAD | HSE Management | Construction Projects | Automotive Manufacturing Industry | Government Compliance.
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1-Preparation of Hazard Identification Risk Assessment (HIRA): In the first step HIRA document will be prepared with existing and additional control measures. In control measure more focus on possible engineering control to reduce the risk probality. 2. Implantations: In the second step we will implement the identified control measures on production site. 3. Communication: The 3rd step is to communicate the risks and their mitigation measures effectively. This helps you to inform, educate, and engage the stakeholders, such as the management, the workers, the customers, the suppliers, the regulators, and the public. You can use various methods and tools to communicate risks through meeting and tool box talks.

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4 Risk monitoring

The fourth step is to monitor the risks and their mitigation measures regularly. This helps you to track the performance, detect any deviations or anomalies, and evaluate the results. You can use various methods and tools to monitor risks, such as sensors, indicators, alarms, reports, dashboards, audits, reviews, and feedback. The goal is to ensure the compliance, quality, and safety of the automated systems.

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5 Risk communication

The fifth step is to communicate the risks and their mitigation measures effectively. This helps you to inform, educate, and engage the stakeholders, such as the management, the workers, the customers, the suppliers, the regulators, and the public. You can use various methods and tools to communicate risks, such as meetings, presentations, newsletters, posters, brochures, websites, social media, and media. The goal is to increase the awareness, understanding, and trust of the stakeholders.

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6 Risk improvement

The sixth and final step is to improve the risks and their mitigation measures continuously. This helps you to learn from the experience, identify any gaps or weaknesses, and implement any changes or enhancements. You can use various methods and tools to improve risks, such as benchmarks, standards, best practices, lessons learned, root cause analysis, and improvement plans. The goal is to optimize the performance, reliability, and security of the automated systems.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you manage risks in industrial automation?

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1 Risk identification

2 Risk assessment

3 Risk mitigation

4 Risk monitoring

5 Risk communication

6 Risk improvement

7 Here’s what else to consider

Plant Engineering

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