OSR023
Rationalise safety controls by removing redundant layers and automating key protections to reduce operational complexity without lowering functional safety integrity.
CyberTRIZ analysis · BrownFieldIndustrialProjects contradiction C13-OSR023 · one of 8,235 worked contradictions published by CyberTRIZ.AI
Regulations
Failure Prevention vs Operational Complexity
Business ContextAdditional alarms, interlocks, procedures, protection layers, and operating restrictions can reduce specific failure risks. Accumulating too many controls can make systems harder to operate, troubleshoot, and understand, potentially creating new human and technical failure mechanisms.
Brown Field Industrial Projects TRIZ ResolutionPrioritize controls that eliminate or directly detect important failure mechanisms and remove redundant or low-value complexity. Passive protection and automated responses can replace procedural burden where appropriate.
Applicable TRIZ Principles
Principle 2 – Taking Out: removes unnecessary or duplicative controls.
Principle 6 – Universality: combines compatible protective functions.
Principle 25 – Self-Service: enables systems to perform appropriate protective actions automatically.
Expected Outcome
Stronger failure prevention
Simpler operation
Reduced procedural burden
Easier troubleshooting
Decision IndicatorsEarly indicators that this contradiction is limiting brownfield project performance include:
Operators manage increasing numbers of overlapping controls.
Protection additions create frequent nuisance alarms or trips.
Procedures become increasingly difficult to execute consistently.
New safeguards duplicate existing functions.
Troubleshooting becomes harder after reliability modifications.
Monitoring these indicators helps organizations prevent failures without making the operating system unnecessarily complex.