6-5. Learning from a Factory Fire: The Risk of Perfunctory Equipment Inspections

Factory fires are often caused by inadequate equipment inspections and perfunctory management systems. When inspections are merely a formality and do not achieve their true purpose of identifying and preventing risks, the danger of a serious accident increases. This article discusses the risks posed by superficial equipment inspections and the recurrence prevention measures companies should take, based on examples of factory fires.

1. The Risks of Superficial Equipment Inspections

Inspections are a critical process for detecting abnormalities in machinery and electrical systems early to prevent accidents. However, in practice, inspections can become a formality, where workers simply follow a checklist and mark off items. When inspectors lack sufficient knowledge or skills and perform checks as a routine task, there's a risk they will miss signs like deteriorating wiring, oil leaks, or abnormal vibrations and heat. This "going through the motions" approach leaves potential fire risks unaddressed.

2. Typical Examples of Factory Fires

In one chemical factory, a fire was caused by sparks from deteriorating electrical wiring insulation. Although inspection records showed "no abnormalities," it was later found that a detailed check had not been performed and the long-term deterioration had been neglected. In an automobile parts factory, a fire started from accumulated oil residue inside a piece of equipment. This fire occurred because the cleaning and inspection process was routinely skipped. These are classic examples of how a lack of thorough inspections can directly lead to serious accidents.

3. Underlying Causes of Perfunctory Inspections

The main reasons for superficial inspections are time constraints due to cost cutting and labor shortages. Additionally, inspectors themselves may be overconfident, believing that "accidents rarely happen," which can lead them to overlook dangers. Furthermore, if management views inspections as a mere obligation and fails to invest in improvements and training, the problem can worsen.

4. Initiatives to Prevent Recurrence

To make equipment inspections effective, the following measures are recommended:

• Implement Risk-Based Inspection (RBI): Focus on high-priority equipment and high-risk areas to optimize inspection frequency and methods.

• Utilize IoT Sensors: Monitor temperature, vibration, and electrical leakage in real time to detect abnormalities that are easy for humans to miss.

• Enhance Education and Training: Train inspectors to develop the skills needed to make concrete judgments about signs of abnormalities and move beyond just checking off items on a list.

• Ensure Management Involvement: Management must view inspection systems not as a cost but as an "investment in accident prevention" and secure adequate resources.

5. The Perspective of Enhancing Corporate Value

A fire can lead to not only injuries and operational shutdowns but also a loss of corporate credibility and a negative impact on the entire supply chain. On the other hand, establishing an effective inspection system can reduce risks and enhance the brand value of a company as a "safe enterprise."

In conclusion, factory fires clearly demonstrate the dangers of superficial equipment inspections. Companies must recognize the true purpose of inspections and build an effective system that combines modern technology with personnel training to prevent fire risks and achieve safe and sustainable business operations.