Respond to Hazards Rationally

Do we have to put a waning label on for every hazard?  We can’t idiot-proof our products!  No matter what we do, some fool will find a way to hurt himself. If we put a warning label on for everything, all you’ll see is warning labels!

These are some of the questions and comment I often receive at products liability seminars.  Manufacturers are understandably frustrated and confused about what needs a warning and how to decide.  Last week’s tip on conducting a hazard analysis is the first step.  But once you have the hazards identified, and dealt with those you can design out or shield, what about the rest?

ANSI Z535.4 Product Safety Signs and Labels, sets out the definitions of the signal words DANGER, WARNING, and CAUTION:

            DANGER:      Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

            WARNING:     Indicated a potentially hazardous situation which, if not avoided, could result in death or serous injury.

            CAUTION:      Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

As you can see, the two variables considered are 1) the severity of the injury and 2) the likelihood of that result.  You can use these two to determine what needs a label. 

If a hazard is DANGER-level, it should usually have an on-product label (or have been designed out or shielded already!).  If the hazard is a WARNING-level, you will have to determine how likely it is that the user will encounter the hazard.  If it’s unlikely, you can probably deal with that hazard in the manual.  On the other hand, if it’s quite likely that the user will encounter the hazard, then an on-product label is in order.  Most CAUTION-level hazards can be dealt with in the manual, without the need for a label on the product.