Operational Control Model Based on Integrated Failure Analysis and Risk Assessment in Sustainable Technological Processes

The simultaneous fulfillment of quality, environmental, and occupational safety requirements is a difficult task. The process flow is influenced by numerous factors, and different operational objectives are pursued in different ways. Methodologies reflecting the use of various models, methods, and tools in the integration and implementation of operational goals dedicated to sustainable operation are becoming increasingly important. The subject of the study is an operational control model considering the integrated risk and the steps taken under the conditions of “supervised risk” ensured by the monitoring of the operational criteria. The method was developed for coherent risk management, covering its identification, analysis, assessment, and acceptability estimation in the technological process. The methodology for the assessment, considering the quality, environmental, and occupational safety criteria, and based on the application of the unit risk ratio, allows for the determination of the key operational features, and the methodology of the identification of the key technological parameters applying the integrated risk ratio ensures that the crucial technological parameters are highlighted. The application of the algorithm in the heat treatment process confirms both the effectiveness of the proposed model and the correctness of the thesis: the different requirements set for the technological processes can be simultaneously fulfilled via the application of integrated operational control.