Advantages for risk assessment: Evaluating learnings from question sets inspired by the FRAM and the risk matrix in a manufacturing environment

The use of the risk matrix as a hazard management tool is a significant issue for industry due to (i) documented pitfalls and (ii) an attention to negative outcomes. Question sets inspired by the Functional Resonance Analysis Method (FRAM) were evaluated to understand if an alternative approach offered a more effective means of risk assessment, and thus was of greater value to both the stakeholders and the organisation. Iterative evaluations were limited to four work systems within a manufacturing environment. A FRAM based approach meant that total systems were considered in addition to the hazards and controls within them, and in doing so safety and productivity were assessed as one activity. In contrast, comparative risk matrix assessments did not provide enough requisite variety to understand the complete picture, only specific hazards and their controls in isolation. For each of the systems investigated work-as-done had been adapted in response to introduced variability to maintain success. The FRAM perspective provided by the use of the question sets afforded the identification of higher order controls though collaboration with all stakeholders. It is concluded that developed narratives provide deeper learnings of system performance in the management of variability.