Researcher pushes ‘safety-first’ revolution in engineering education

Tolulope Oke

As industrial processes become faster and more complex, the traditional ‘speed at all costs’ mindset in engineering is facing a critical reckoning. Gbenga Ajenifuja, a researcher at Western Illinois University, is spearheading a movement to change how the next generation of engineers is trained. His recent work advocates for a Safety-First design framework that proves safety and high-level efficiency are not opposing forces, but two sides of the same coin.

For decades, engineering technology labs have operated with a singular focus: optimization. Whether it is maximizing the output of a chemical reaction or reducing the cost of mechanical parts, the goal has always been to do more with less. However, Ajenifuja points out a dangerous flaw in this approach: safety is often treated as a ‘post-design’ checklist rather than a foundational requirement.

“Traditionally, optimization efforts in laboratories have focused narrowly on performance, cost-efficiency, and throughput”, Ajenifuja notes in his research. When safety is ignored during the design stage, it creates “fragmented” systems where potential hazards are only noticed after an accident occurs. This reactive culture has led to tragic consequences in academic settings, such as the 2008 UCLA lab fire and the 2010 chemical explosion at Texas Tech University.

Ajenifuja’s research highlights a significant “academic gap”. While students graduate with expert knowledge in tools such as Six Sigma and Lean Manufacturing, they often lack the skills to identify hidden risks in the systems they build.

Ajenifuja suggests closing this gap by integrating three key industrial hazard analysis tools into engineering education. First, the Hazard and Operability Study provides a systematic approach to identify operational deviations before they become risks. Second, Failure Mode and Effects Analysis (FMEA) enables students to predict how individual components might fail and understand the potential consequences. Lastly, Inherent Safety Design teaches future engineers to select inherently safer materials and processes, effectively reducing risk at its source by using non-toxic alternatives and smaller storage volumes.

By making these tools as standard as a calculator in the classroom, Ajenifuja believes we can prepare students for real-world industrial settings where safety and performance are inseparable.

The most innovative aspect of Ajenifuja’s work is the push for Multi-Objective Optimization (MOD). Instead of choosing between a ‘fast’ design and a ‘safe’ design, new computational models allow engineers to treat safety as a key performance metric, just like speed or cost.

Safety should be viewed as a foundational element of all process development, Ajenifuja argues. Using advanced simulation software such as MATLAB and ANSYS, researchers can now test how a system handles ‘abnormal’ scenarios in a virtual environment before a single piece of equipment is turned on. This approach reduces operational risks while actually lowering long-term maintenance costs.

The research concludes that a cultural and institutional shift is necessary. Ajenifuja calls on accreditation bodies and universities to mandate that safety-integrated frameworks be part of every laboratory operation. This ensures that engineering labs are not just places of innovation, but safe, sustainable environments that reflect the highest professional standards.

As we look toward the next decade of engineering, the ‘Safety-First’ model provides a roadmap for building a more resilient and ethically sound industry. By treating safety as a driver of innovation rather than a barrier, Ajenifuja is helping to ensure that the engineers of tomorrow are prepared for the complexities of the modern world.