Hierarchy of Controls

Hierarchy of Controls -

Applying Engineering Solutions to Life 

Thoughts become Emotions, Emotions build Energy, Energy leads to Actions and Actions to Things that one can touch and feel. It is these things, that make or break life.

Hierarchy of Controls is a well applied methodology in the Manufacturing Industry - be it for Product-Process Design, Failure Modes, Control Plans, Health & Safety and many such more. How about applying this, at the very fundamental level - Our Thoughts

Elimination is the highest level of Control. In Manufacturing, there are several activities that make up a process. Certain practices might have been initially introduced when the Process was designed, given the limitations at that time. Over a period, these activities tend to cause more harm than good. For instance visualise two wooden planks being fit together using a nail & a hammer. The nail & hammer are hazards that can potentially lead to a defective crack in the product or an injury like smashed finger. How about eliminating this nail & hammer altogether with a design change that does not need it - say a snug fit design.

At times, Elimination is altogether not possible. Substitution is the next best control. Over the years, in most cases, nails & hammers have been replaced with screws & screw drivers. There goes the possibility of smashed Fingers with this introduction & so does the chances of cracking. The European union was the first to substitute the toxic lead used in mobile phones with Silver.

Isolate / Transfer is the control method that is well adopted in Clinical research & Medical care. Did we not hear this word Isolation more than enough for a lifetime during Covid. During research, when scientists are able to isolate a bacteria or virus, they shout 'Eureka'; because this is the first step to develop a cure - a control. Of course this control is applicable across the industry.

Engineering Controls have been the most popular measures picking pace & adoption over the last 50 odd years. Be it simple limit switches, automatic sensors, guided arms or to the current advanced pick & place systems. These controls while increased productivity multi-fold, have at the same time, saved many a life.

We humans need to be reminded of requirements, purposes & hazards repeatedly, for we tend to move tangentially, given our nature of being. Administrative Controls, for want of a better need, serve this purpose at a bare minimum. Warning Signals, Barricades, Security personnel & Watch dogs are frequently deployed as a control. Unfortunately these bring in more fear and panic rather than benefit. On the other hand, Trainings, Instruction boards, Engagement of People in decision making are bound to have positive impacts when well utilised as Control

The above Controls can fail, or when they are not in place, which at times is bound to happen, Personal Protection comes to the rescue. You dont wear a helmet while riding a bike assuming that that you will never fall. You might be the best of riders, but who knows about how devastating a small pot hole can be or, for that matter, an erring motorist / car coming in the wrong direction from a blind curve. It will not prevent the accident, but the impact can be certainly lower. The same is with using gloves while baking in an oven, fall protection gear in adventure sports or a bullet proof vest in war. Term Life Insurances serve this purpose

Now apply this analogy to my opening remarks. Eliminate unwanted thoughts; replace disturbing thoughts; isolate painful thoughts; apply your own limit switches for wandering thoughts; administer your thoughts with insightful readings; books, messages & positive people. Finally Protect yourself with good self care & hygiene.


Enhancing Warehouse Fire Safety