Failure of porcelain cutouts has occasionally occurred in the BC Hydro, distribution overhead system, which often resulted in cutouts falling apart or a live conductor swinging. This situation is very hazardous to both BC Hydro crews and the public. The failures were usually attributed to cracked cutouts subjected to internal or external loading from a combination of the manufacturing process and the electrical, mechanical and environmental operating conditions. To mitigate the risk, a risk assessment model was developed and used to manage BC Hydro porcelain cutouts, which includes condition assessment through random sampling, reliability testing and analysis, risk and cost-benefit analysis.