Process Safety with Trish & Traci Challenger Disaster 40 Years Later: The Deadly Cost of Reversing Safety Burden
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Jan 13, 2026 The discussion kicks off with a tense pre-launch meeting where engineers debated safety amid uncertainty. They delve into the tragic Challenger disaster, highlighting the failure of O-rings in freezing temperatures. A crucial takeaway emphasizes reversing the burden of proof, shifting the focus to requiring evidence of safety. They explore how simple demonstrations, like the famous iced-water test, can effectively convey risks. Lastly, the importance of protecting technical authority is stressed, ensuring engineers feel safe to halt unsafe operations.
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Engineers Pressured Into Fatal Release
- Engineers debated overnight about releasing a product they couldn't prove safe and were pressured by management and customers. The next morning the released product killed seven people, paralleling the Challenger decision chain.
Cold Made O-Rings Brittle
- Cold temperatures made the O-rings brittle and they failed to seal during the Challenger launch. The resulting hot gas blow-by destroyed the shuttle about 71 seconds after launch.
Past Success Lulls Us Into Risk
- Humans default to 'it's fine' when past outcomes were safe, which reverses the burden of proof. That bias masks weak signals like recurring blow-by until catastrophe occurs.