APPENDIX D: HAZARD ANALYSIS
Potential Hazard Likelihood Severity of Consequence Risk Assessment Plan

Leg being too far out from bike on left side could cause hip problems

Frequent

Marginal

I
Intolerable

Client did not feel a difference during test
Mill fasteners and crank arm as thinly as possible
Used only one fastener in final design
Used thinner crank arm in final design

Pull foot up and out of pedal cycle could force client to flex knee more than she is able

Occasional

Marginal

III
Tolerable

Do not use clip-in pedals
Client did not see this as a problem during test as long as non-clip-in pedals are used

Parts loosening/wearing
could result in disassembly during riding and cause injury

Remote

Critical

III
Tolerable

Use nylon-insert nuts in final construction.
Use needle bearing to reduce rotational friction, thus decreasing likelihood of disassembly.

Sharp metal edges on milled crank arm  could cut user

Remote

Marginal

III
Tolerable

Round edges smooth  to resemble typical crank arm after machining

Pivot joint locked while turning; If it locks in straight position, this could force user into a motion that is painful for her

Frequent

Critical

I
Intolerable

Fixed by using a shoulder screw with shorter threading that will not tighten into overlapping fastener, which was causing the locking.  The needle bearing will encase the shoulder screw.

Pivot joint becomes stiff, causing user to exceed maximum flexion

Occasional

Critical

II
Undesirable

Surrounded shoulder screw with thrust bearing and washers to protect from debris entering connection, which would cause this stiffness