Product Safety Excellence

Timothy A. Pine

Description

Product safety problems really waste company resources, alienate consumers, frustrate employees, and leave company stakeholders disgusted. It is easy to understand why most consumer product companies are committed to product safety and why they often seem willing to devote even more resources to increase their organization’s safety commitment. Their logic seems to be that this kind of action will result in higher levels of safety performance.
Achieving excellence in product safety is not about seeking more commitment. It is all about understanding what to do and how to do it using the fine organization one already has.
Product Safety Excellence defines the seven vital elements that are essential to achieving state-of-the-art product safety performance with the benefits of product liability prevention, product quality improvement, and higher levels of consumer trust and loyalty.
This book is appropriate for anyone interested in understanding the concepts underlying product safety excellence. It should especially be read by management and technical personnel with a responsibility and/or desire for eliminating product safety problems and improving profitability and consumer loyalty.

Sujets

• Business
• Qualité, hygiène, sécurité, environnement
• Total Quality Management
• Gestion et management
• Economics

Informations

• Publié par: ASQ Quality Press
• Date de parution: 18 juin 2012
• Nombre de lectures: 0
• EAN13: 9780873891608
• Langue: English

Extrait

Product Safety Excellence
The Seven Elements Essential for Product Liability Prevention
Timothy A. Pine
ASQ Quality Press
Milwaukee, Wisconsin
American Society for Quality, Quality Press, Milwaukee 53203
© 2012 by ASQ
All rights reserved.
Library of Congress Cataloging-in-Publication Data
Pine, Timothy A., 1949–
Product safety excellence : the seven elements essential for product liability prevention / Timothy A. Pine.
p. cm.
ISBN 978-0-87389-842-3 (alk. paper)
1. Product safety. 2. Product design. 3. Consumer protection. 4. Products liability. I. Title.
TS175.P56 2012
363.19—dc23
2012013749
No part of this book may be reproduced in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher.
Publisher: William A. Tony
Acquisitions Editor: Matt Meinholz
Project Editor: Paul Daniel O’Mara
Production Administrator: Randall Benson
ASQ Mission: The American Society for Quality advances individual, organizational, and community excellence worldwide through learning, quality improvement, and knowledge exchange.
Attention Bookstores, Wholesalers, Schools, and Corporations: ASQ Quality Press books, video, audio, and software are available at quantity discounts with bulk purchases for business, educational, or instructional use. For information, please contact ASQ Quality Press at 800-248-1946, or write to ASQ Quality Press, P.O. Box 3005, Milwaukee, WI 53201-3005.
To place orders or to request a free copy of the ASQ Quality Press Publications Catalog, visit our website at http://www.asq.org/quality-press .

To Pat, a remarkable and lovely wife, friend, patriot, Christian, and mother of our children.
Table of Contents
Preface
Acknowledgments
1
Introduction
Excellence vs. Perfection
Invest in Prevention
Design Defects and Recalls
Voluntary and Regulatory Requirements and Recalls
Comprehension vs. Commitment
The Seven Vital Elements
2
Technical Collaboration
Discovering Needed Knowledge
NEISS Information
CPSC Recall History
Trade Associations
Medical Expertise and Academia
Laboratories and Consulting Firms
Partner Supplier Input
Benchmarking and Competition
Summary
3
Concept Evaluation
Early Safety Influence
Hazard Identification Checklists
Energy-Hazard Relationship
Foreseeable Use and Misuse
Human Factors
Technical Collaboration Input
Warning Label Problems
Concept Risk Assessment
4
Design Qualification
Design Review
Safety Checklist
Reliability
Process Capability Analysis
Safety Specification Development
Claim Substantiation
Summary
5
Supplier Qualification
Quality Systems Audit
Management Commitment
Supplier Capabilities and Capacities
Manufacturing Agreement
Change Control
Strategic Partnership
6
Product Qualification
Production Process Documentation
Production-Representative Samples for Test
Testing to Failure
Factor of Safety
Test Documentation
7
Supplier Quality Process
Precontrol and Positrol
Certifications
Error Avoidance (Poka-Yoke)
Performance Metrics and Trends
Management Reviews
8
Strategic Auditing
Auditing Supplier Performance
Consumer Complaints
Defect Analysis
Knowledge Database
Converting Data into Wisdom
Summary
9
Conclusion
Error-Prevention Process
Product Liability Prevention
Product Safety Excellence
Appendix A
Quiz
Appendix B
Answers to the Quiz
Preface
P roduct safety problems are very damaging to companies, their names, and their brands. They cause injuries, lawsuits, recalls, penalties, complaints, returns, schedule delays, scrap, and rework. They waste company resources, alienate consumers, frustrate employees, and leave company stakeholders disgusted.
It is easy to understand why most consumer product companies are committed to product safety and why they often seem willing to devote even more resources to increase their organization’s safety commitment. Their logic seems to be that this kind of action will result in higher levels of safety performance.
Achieving excellence in product safety is not about seeking more commitment. Most organizations are already very committed to product safety—just ask them. Achieving product safety excellence is all about understanding what to do and how to do it using the fine organization one already has.
Product Safety Excellence defines the seven vital elements that are essential for achieving excellence in product safety, and it describes the tools and processes that make up each element. The application of these seven elements will provide a proven system for ­state-­of-the-art consumer product safety performance with the benefits of product liability prevention, product quality improvement, and higher levels of consumer trust and loyalty.
This book is appropriate for anyone interested in understanding the concepts underlying product safety excellence. It should especially be read by management and technical personnel with a responsibility and/or desire for eliminating product safety problems and improving profitability and consumer loyalty. I have attempted to make Product Safety Excellence concise, clear, and easy to read by anyone with some general business experience or knowledge.
My sincere hope and prayer is that this book will help guide and inspire individuals and organizations toward higher levels of performance and ­state-­of-the-art product safety.
Acknowledgments
So whoever knows the right thing to do and fails to do it, for him it is sin.
—James 4:17 ESV
P roduct safety information and best practices are really meant to be shared within companies, between companies, and between industries. Promoting safety with this type of sharing is a responsibility of all companies. It is recognized that if one company has a serious product safety failure, it adversely affects, to some extent, all companies in that industry. Sharing best practices, therefore, benefits all companies.
I am truly thankful and appreciative for all of the great companies I have either worked for or been affiliated with that have strongly supported benchmarking and the sharing of information for the purpose of advancing product safety. I am even more thankful for the opportunity to have worked directly with so many excellent individuals to achieve, support, and advance product safety initiatives. There are several in particular whom I must name because of their outstanding support and contributions: Kathrin Belliveau, Sandra Biets, Marty Cahill, KS Chan, Ken Collins, Scott Crump, Sean Flanagan, Joe Fortino, Jenny Foster, Jim Hanners, Lindsay Harris, Denis Hogya, William Ip, Ron Jackson, Gary Jones, Jerry Karver, Jill Kashiwagi, Arthur Kazianis, Jim Kipling, John Kraus, Mary Kuo, Dave Mauer, Joe Mendelsohn, Kitty Pilarz, Bill Quinlan, Gerry Remmy, Terri Rogers, Tim Schuh, Daryl Scrivens, Vincent Tam, KL Tsui, Chris Vacca, Fred Virrazzi, Karl Wojahn, and CK Wong.
I especially want to thank Gary Jones, a close friend and highly respected ­longtime associate, for providing valuable and insightful comments on the first draft.
I must also thank Karl Wojahn in particular for the abundance of education, training, mentoring, encouragement, and support he provided me throughout my career. Without it, I never would have been able to write this book.
And finally, a special ­thank-­you goes to Pat Pine, my loving wife, confidante, and life partner, for conscientiously and thoroughly reviewing early drafts and providing brilliant critiques when I know she would have much rather been reading entirely different and less technical material.
My sincere thanks go to all of you.
Timothy A. Pine
March 2012
1
Introduction

E ffective product safety management is really all about preventing errors. This means focusing on product and process design, understanding consumer behavior with respect to product use and misuse, applying human factors, performing thorough risk assessments, and maintaining an awareness of emerging hazards and diverse medical and technical information. It is not about just meeting mandatory and voluntary standards, product testing to these standards, inspecting product, or adding lots of warnings. This book defines what product safety excellence is all about and describes how to apply the appropriate tools and processes to achieve it.
Excellence vs. Perfection
There is no such thing as a perfectly safe product. In product safety, perfection is just not possible. Virtually anything can be unsafe or hazardous if it is misused or abused. A bucket of water can be a drowning hazard to a ­top-­heavy toddler who leans over to look inside the bucket. A grape has been known to cause choking fatalities in young children. Even a crayon can easily break into small parts that can create an asphyxiation hazard to children. Clearly, it is impossible to eliminate all hazards from any product.
Hazard
A hazard is defined as a potential source of harm. Harm can be personal injury and/or property damage. Hazards can range from the relatively minor (e.g., a sharp point) to the very severe (e.g., high toxicity or electrocution). Hazards can also range from a relatively ­low-­exposure “inaccessible” to a relatively high-­exposure 100% accessible. For example, an exposed 115-volt (household current) metal part presents a severe hazard if the exposure is high; that is, it is readily accessible to the touch or incidental contact. This same metal part contained within the insulated housing of a toy oven presents the same severe hazard but with a very low, inaccessible exposure. Although the hazard is the same whether the 115-volt part is accessible or inaccessible, the risk of injury is clearly not the same.
Risk
The term risk is used to express the combination of hazard severity and hazard exposure (probability of harm). Risk is the product of “probability of harm” and “severity of that harm.” Risk is the mos