Health and Safety Risk Assessment Using a Combined FMEA and JSA Method in a Manufacturing Company
DOI:
https://doi.org/10.31557/apjec.2019.2.1.63-68Keywords:
Safety and Health Risk Assessment, FMEA, JSA, AHA, JHA, THA, Executive Procedure, Guidelines.Abstract
Background: Occupational accidents cause three to four times as many deaths in developing countries as industrialized countries. There are about 14,000 accidents in Iran every year, most of them involving workers in industries, To reduce these accidents, it is necessary to use risk assessment, which is a rational approach to hazard assessment and to identify hazards and potential consequences, on individuals, materials, equipment and the environment to reduce the risks of workplace accidents and consequently work-related accidents.
Methods: This study was carried out in 1998 as an analytical-applied study in a manufacturing company. The Risk Assessment process, first with the formation of the relevant team, is selected from technical and production specialists who are more familiar with the concept of safety and risk assessment and again how to perform the Risk Assessment and Identify the risks involved, using the JSA Integrated Method for the analysis of business components and associated risks and FMEA method was trained and targeted to determine system failure states as well as assign risk priority number (RPN).
Results: Risk assessment was carried out in 4 aspects, locations, equipment, main and sub-units and activities leading to the preparation of tables related to the risk assessment guide of locations, equipment, activities, RPN calculation, risk level classification and identification forms.
Conclusions: In this study, 166 hazards were identified and, through follow-up and collaboration with senior management of the organization from 38 risks of fluids production hall, 22 corrective action (57.89%), from 46 risks of solids production hall, 37 corrective action (80.43%), from 33 risks of product warehouse, 28 corrective actions (84.84%), from 30 risks of raw materials warehouse, 21 corrective actions (70%), from 19 risk of incendiary materials, 10 corrective actions (52.63%) were performed. The overall results of the study showed that the major risk in the studied units was related to the dangers of inadequate cabling and placement of people in these work situations.
key words: Safety and Health Risk Assessment, FMEA, JSA, AHA, JHA, THA, Executive Procedure, Guidelines.
References
Jozi S, Atabi F, Honarmand H. Management of the Health, Safety and Environmental Risks of the Shomal Cement Factory using the William Fine Technique. Environmental Research. 2014;5(10):23-34.
Yari S, Fallah AA, Varmazyar S. Assessment of semi-quantitative health risks of exposure to harmful chemical agents in the context of carcinogenesis in the latex glove manufacturing industry. Asian Pacific journal of cancer prevention: APJCP. 2015;17(205):11.
Yari S. Assessment of potential risk by the failure mode and effects analysis in an air conditioning equipment manufacturing company. Journal of Safety Promotion and Injury Prevention. 2017;5(2).
Nivolianitou Z. Risk analysis and risk management: a European insight. Law, Probability and Risk. 2002;1(2):161-74.
Kim E-A, Kang S-K. Historical review of the List of Occupational Diseases recommended by the International Labour organization (ILO). Annals of occupational and environmental medicine. 2013;25(1):14.
Ericson CA. Hazard analysis techniques for system safety: John Wiley & Sons; 2015.
Kouhnavard B, Aghanasab M, SAFAEI R, FAZLI Z. RiskIdentification and Assessment, UsingJob Safety Analysis, in anAffiliated AgencytoIran KhodroCompany, 2014. 2015.
Shahraki A, Moradi M. Risk evaluation in the workplace using fuzzy multi-criteria model. Iran Occupational Health. 2013;10(4):43-54.
Rothstein MA. Occupational safety and health law: West Group; 1990.
Rozenfeld O, Sacks R, Rosenfeld Y, Baum H. Construction job safety analysis. Safety science. 2010;48(4):491-8.
mohammad fam I. Safety techniques job safety analysis: fanavaran 2006.
Tooranloo HS, sadat Ayatollah A. A model for failure mode and effects analysis based on intuitionistic fuzzy approach. Applied soft computing. 2016;49:238-47.
Chai KC, Jong CH, Tay KM, Lim CP. A perceptual computing-based method to prioritize failure modes in failure mode and effect analysis and its application to edible bird nest farming. Applied Soft Computing. 2016;49:734-47.
Wang W, Liu X, Qin Y, Fu Y. A risk evaluation and prioritization method for FMEA with prospect theory and Choquet integral. Safety science. 2018;110:152-63.
Liu H-C, Li Z, Song W, Su Q. Failure mode and effect analysis using cloud model theory and PROMETHEE method. IEEE Transactions on Reliability. 2017;66(4):1058-72.
Certa A, Hopps F, Inghilleri R, La Fata CM. A Dempster-Shafer Theory-based approach to the Failure Mode, Effects and Criticality Analysis (FMECA) under epistemic uncertainty: application to the propulsion system of a fishing vessel. Reliability Engineering & System Safety. 2017;159:69-79.
Tsai S-B, Yu J, Ma L, Luo F, Zhou J, Chen Q, et al. A study on solving the production process problems of the photovoltaic cell industry. Renewable and Sustainable Energy Reviews. 2018;82:3546-53.
Deng Y, Li Q, Lu Y. A research on subway physical vulnerability based on network theory and FMECA. Safety science. 2015;80:127-34.
Mohsen O, Fereshteh N. An extended VIKOR method based on entropy measure for the failure modes risk assessment–A case study of the geothermal power plant (GPP). Safety science. 2017;92:160-72.
Normohammadi M, Kakooei H, Omidi L, Yari S, Alimi R. Risk assessment of exposure to silica dust in building demolition sites. Safety and health at work. 2016;7(3):251-5.
Mikulak RJ, McDermott R, Beauregard M. The basics of FMEA: Productivity Press; 2008.
ARP S. Recommended Failure Modes and Effects Analysis (FMEA) Practices for Non-Automobile Applications. Warrendale: Society of Automotive Engineers. 2001.
Mode PF. Effects analysis in design (design FMEA) and potential failure mode and effects analysis in manufacturing and assembly processes (process fmea) reference manual. Society of Automotive Engineers, Surface Vehicle Recommended Practice J. 2002;1739.
Liu H-C, Liu L, Liu N, Mao L-X. Risk evaluation in failure mode and effects analysis with extended VIKOR method under fuzzy environment. Expert Systems with Applications. 2012;39(17):12926-34.
Chang K-H, Chang Y-C, Tsai I-T. Enhancing FMEA assessment by integrating grey relational analysis and the decision making trial and evaluation laboratory approach. Engineering Failure Analysis. 2013;31:211-24.
Zhang Z, Chu X. Risk prioritization in failure mode and effects analysis under uncertainty. Expert Systems with Applications. 2011;38(1):206-14.
Liu H-C, Liu L, Liu N. Risk evaluation approaches in failure mode and effects analysis: A literature review. Expert systems with applications. 2013;40(2):828-38.
Yang Z, Wang J. Use of fuzzy risk assessment in FMEA of offshore engineering systems. Ocean Engineering. 2015;95:195-204.
Liu H-C, You J-X, Shan M-M, Shao L-N. Failure mode and effects analysis using intuitionistic fuzzy hybrid TOPSIS approach. Soft Computing. 2015;19(4):1085-98.
Chang K-H. Generalized multi-attribute failure mode analysis. Neurocomputing. 2016;175:90-100.
Wang Z, Gao J-M, Wang R-X, Chen K, Gao Z-Y, Zheng W. Failure mode and effects analysis by using the house of reliability-based rough VIKOR approach. IEEE Transactions on Reliability. 2017;67(1):230-48.
Safari H, Faraji Z, Majidian S. Identifying and evaluating enterprise architecture risks using FMEA and fuzzy VIKOR. Journal of Intelligent Manufacturing. 2016;27(2):475-86.
Fattahi R, Khalilzadeh M. Risk evaluation using a novel hybrid method based on FMEA, extended MULTIMOORA, and AHP methods under fuzzy environment. Safety science. 2018;102:290-300.
Health GB, Executive S. The tolerability of risk from nuclear power stations: HMSO; 1992.
Roughton J, Crutchfield N. Job hazard analysis: A guide for voluntary compliance and beyond: Butterworth-Heinemann; 2011.
Luxhoj JT. Probabilistic causal analysis for system safety risk assessments in commercial air transport. 2003.
Yari S, Saeidabadi H. Simulation the Probability of Liberalizing Chlorin Gas from Urban Water Chlorination System in Alborz: With the Cancer Approach. 2019.
Madarsara TJ, Yari S, Saeidabadi H. Assessment and evaluation of occupational stress among safety authorities: By possibility of cancer. Asian Pacific Journal of Environment and Cancer. 2019;2(2).
Kausek J. OHSAS 18001: Designing and implementing an effective health and safety management system: Government Institutes; 2007.
Jordan T. The ISO 45001: 2018 Implementation Handbook: Guidance on Building an Occupational Health and Safety Management System. Quality Progress. 2019;52(1):54-.
M J, MA NC. Risk assessment & management: Fanavaran 2016.
AH A. Techniques of safety management: Fanavaran 2010.
Albrechtsen E, Solberg I, Svensli E. The application and benefits of job safety analysis. Safety science. 2019;113:425-37.
Ebrahimzadeh M, Halvani G, Mortazavi M, Soltani R. Assessment of potential hazards by failure modes and effect analysis (FMEA) method in Shiraz oil refinery. Occupational Medicine Quarterly Journal. 2011;3(2):16-23.
Mortazavi SB, Mahdavi S, Asilian H, Arghami S, Gholamnia R. Identification and assessment of human errors in srp unit of control room of tehran oil refinery using heist technique (2007). 2008.
HALVANI G, RADPOUR J, SHOJA E, GHOLAMI S, KHALIFEH Y. THE EFFECT OF TRAINING ON RISK ASSESSMENT CODE WITH THE METHOD OF QUANTIFIED JOB SAFETY ANALYSIS IN ONE OF THE UNITS OF ABYEK CEMENT PRODUCTION PLANT. 2016.
Yari S. Inherent safety design in compose of urban gas station. Safety Promotion and Injury Prevention. 2015;3(2):135-40.
Yari S, Akbari H, Gholami Fesharaki M, Khosravizadeh O, Ghasemi M, Barsam Y, et al. Developing a model for hospital inherent safety assessment: Conceptualization and validation. International Journal of Risk & Safety in Medicine. 2018;29(3-4):163-74.
Yari S, Naseri MH, Akbari H, Shahsavari S, Akbari H. Interaction of Safety Climate and Safety Culture: A Model for Cancer Treatment Centers. Asian Pacific Journal of Cancer Prevention. 2007;20(3):961-9.
Normohammadi M, Asadi AF. Job Stress and Safety Climate in Cancer Treatment Centers: Upgraded Model for Dimensions. Asian Pacific Journal of Environment and Cancer. 2018;1(2).
Monfared M, Yari S, Jafari M, Maher A. The relationship between safety management and patient safety culture in Cancer Treatment Centers. Asian Pacific Journal of Environment and Cancer 2019; 2 (1).
Maher A, Monfared M, Jafari M. The relationship between safety management and patient safety culture in Cancer Treatment Centers. Asian Pacific Journal of Environment and Cancer. 2019;2(1).
3.jpg)
