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Hazard Identification, Risk Assessment, and Risk Controlling Using

Hazard Identification and Risk Assessment Method
To cite this article: R Aulia and Qurtubi 2019 IOP Conf. Ser.: Mater. Sci. Eng. 598 012123

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Hazard Identification, Risk Assessment, and Risk Controlling

Using Hazard Identification and Risk Assessment Method

R Aulia1 and Qurtubi1

1
Department of Industrial Engineering, Universitas Islam Indonesia, Yogyakarta,
Indonesia

14522459@students.uii.ac.id

Abstract. This article discusses about hazard identification, risk assessment and risk controlling
in a production line 1 in PT. XYZ, a company that focuses its production in engineering,
production, installation (EPI) of concrete industry. Observation and interview are employed as
the method of data collection. The analysis involves Hazard Identification and Risk Assessment.
Based on hazard identification, there are 53 potential hazard occurrences that possibly could
emerged in PT. XYZ, consist of mechanical hazards with 55%, physical hazard of 32%, chemical
hazard of 9% and electrical hazard 4%. Risk potential is calculated as 53% at the high level, 34%
at the moderate level, 11% at the extreme level and 2% at the low level. The controlling that
could be implemented are: the operational process that should fulfil IK (Work Instruction); the
maintenance of alternative tools that fit with lifting capacity; scheduled maintenance, the
instalment of signs, utilization of safety helmet, mask, earplug, safety shoes and gloves; the
appropriate usage of tool as its ideal capacity; to equip operators with SIO, to secure the position
of workers away from railway, maintaining the edge of mold clean from seplit and stirring
materials; to secure the position of the workers away from impact tool range; to install the ladder
inside the steam vessel; to maintain the steam pipe with safe wrapper; to provide the APAR; to
set the pressure of oxygen/LPG; to install the switch and plug-in; to maintain the electricity cable
network well-wrapped with no leaks; to utilize strong wood material for foothold; installing
SPOT HPIT lamp at the line 1.

1. Introduction
Globally, construction industry is considered as important due to its huge size and great output that
supports several of economics activities and contributes to social deliverance and the objective of a
nation. Although, it considered as important, this industry is assessed as the most dangerous and
uncomfortable in most countries. The level of mortality and industrial incidents is higher than average
of all other industries. Hence, it is important for construction industry to manage its safety and improve
the safety performance [1].
Reference [2] argued that there are 84% accidents that could be predicted and avoided if the risk
management is run properly. According to reference [3], there are many areas exposed to risks, such as
heat injury, poor visualization, noise pollution, physical detention and movement limitation
(ergonomics) as well as other inconvenience conditions, such as electricity, spill and mechanical hazards
related to tools.

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

2. Data collection method

Data collection methods applied in this research are observation and interview. The observation was
carried out by direct observation on work activities, while the interview was performed by direct
question answer with the source.

3. Result and discussion

The work procedure in PT. XYZ Production Line 1 Plant is setting up the reinforcement, stressing, the
manufacturing of concrete, casting, the compaction of concrete, steaming, products’ opening, finishing,
stock yard, and the making of pile shoe and power pole cover.
From the result of identification, it was identified 53 potential hazards in Table 1 that could possibly
emerged. The set-up of reinforcement is identified with 9 potential hazards, stressing with 4 potential
hazard, concrete manufacturing with 6 potential hazards, the casting with 6 potential hazards, the
concrete compaction with 3 potential hazards, the steaming with 4 potential hazards, product’s opening
with 8 potential hazards, finishing with 5 potential hazards, stock yard with 6 potential hazards, the
making of pile shoes and the power pole cover was identified with 2 potential hazards. Based on the
type of hazard, it is confirmed that mechanical hazard experiences the largest number of hazards as 55%,
followed by Physical with 32%, chemical with 32% and electricity with 4%.
Table 1. The result of identification on hazard and risk assessment
Assessment
Process Potential of Hazard Impact A P R
Set-up of Structed down by the assembling materials Wound/injury 3 C H
reinforcement Greasy hand Skin irritation 2 B H
Strangulated hand Wound/injury 2 C M
Structed down by mold Fatality 5 D E
Structed down by accessories /end plate Wound/injury 3 C H
Snatched by impact hose Wound/injury 2 C M
Noise of spinning Hearing damage/deaf 1 A H
Higher Trustel for TP 60 Early fatigue 1 C L
Punctured by T tool Wound/injury 3 D M
Stressing Punctured by PC Wire Fatality 5 C E
Broken hydraulic hose Wound/injury 2 C M
Run over by trolley’s wheel Wound/injury 3 C H
The noise of spinning Hearing damage/deaf 1 A H
The making Fall down/batching plant Fatality 3 C H
of concrete Electricity shock Wound/injury 3 C H
Exposed by admixture chemical Respiratory 2 C M
disturbance
Inhale cement’s dust Respiratory 1 A H
disturbance
Strangulated hand Wound/injury 3 C H
Greasy floor Wound/injury 3 C H
Casting Strangulated by molding Wound/injury 3 C H
Run over by hopper Wound/injury 3 C H
Run over by trolley’s wheel Wound/injury 3 C H
Dirty hand by concrete mixture Skin irritation 2 B M

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Assessment
Process Potential of Hazard Impact A P R
Noise of impact tool Hearing damage 2 A H
Exposed by impact tool Wound/injury 2 C M
Concrete compaction Exposed by waste water Skin irritation 2 B H
Hit by a throw Wound/injury 2 C M
Noise Hearing damage 1 A H
Steaming Struck down by Fatality 5 D E
product/molding
Slipped/fall into steaming Wound/injury 2 C M
vessel
The burst of hot steam Burns 3 C H
Noise of a spinning Hearing damage 1 A H
Product’s opening Struck down by Fatality 5 D E
product/molding
Run over by trolley Wound/injury 3 C H
Cylinder explosion (LPG & Wound/injury 4 C E
oxygen)
Sparks (blander/welding) Burns 2 A H
Struck by supporting tools Wound/injury 3 C H
Inhale the painting while Respiratory 2 A H
labeling disturbance
Noise of impact tool Hearing damage 2 A H
Exposed with impact tool Wound/injury 2 C M
Finishing Electricity shock Wound/injury 3 C H
Sparks from grinding Wound/injury 2 A H
Fall from ladder Wound/injury 3 D M
Sun burn Irritation 1 A H
Rain Sick 1 B M
Stock yard Low light at night Uncomfortable 1 B M
Dehydration Skin irritation 1 B M
Struck down by products Fatality 5 D E
Strangulated by products Wound/injury 2 C M
Fall from the piles Wound/injury 3 C H
Rain Sick 1 B M
The making of pile shoes and Strangulated by products Wound/injury 2 C M
power pole cover Dirty hand by concrete mixture Skin irritation 2 B M

From above risk assessment, it can be notified that 53% risk potential with high level is accumulated
with 28 potential risks, 34% of moderate level with 18 potential risks, 11% on the extreme level with 6
potential risks and 2% on the low level with 1 potential risk. The risks' control can be obtained in Table
2, some of the signs is written also in bahasa Indonesia.

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Table 2. Risk controlling

Potential Hazard Impact Controlling
Set-up of reinforcement
Struck down with Wound/injury Operation should fit the IK E
assembling materials
The maintenance of seling tools, which is adjusted with
E
lifting capacity
Scheduled maintenance E
The installment of sign "Awas seling putus"/”beware of
A
broken seling”

Applying safety helmet and shoes and cloth gloves P

Greasy hand Skin irritation Applying rubber gloves P

Strangulated hand Wound/Injury The installment of sign "Awas terjepit"/”beware of
A
being strangulated”
Operator should use cloth gloves P

Struck down by Fatality The utilization of seling tools as capacity E

molding
The routine and scheduled maintenance of seling tools E

The operation should fit the IK E

Operator has SIO A
The installment of sign "Awas seling putus"/”beware of
A
broken seling”

Struck down by Wound/injury The installment of end plate in straight position with E
accessories/end plate bolt hole

The utilization of safety helmet and shoes and gloves P

Snatched by impact Wound/injury

The appropriate setting of air pressure E
hose
Noise of spinning Hearing Using the earplug P
damage/deaf

Trustel that is too Early fatigue

A lower trustel or a trustel situated on the floor is made E
high for TP 60
Punctured by T tools Wound/injury To ensure the absence of people around its reach
Stressing
Punctured by PC Wound/injury Install the safety board E
wire Install the sigh of "Awas PC Wire putus"/”Beware of
A
broken PC Wire”
Broken hydraulic Wound/injury Hose should be fit with seling capacity E
hose

Wound/injury Workers better stand away from railway A

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Potential Hazard Impact Controlling

Run over by trolley’s
The utilization of safety shoes P
wheel
The noise of Hearing Applying earplug P
spinning damage/deaf

The making of concrete

Falling down / Fatality Construct the safety fence E
batching plant Installing the sign of "Awas terjatuh"/”Beware of
A
falling down”
Electricity Shock Wound/injury Wrapped cable E
Installing the sign of "Awas tersengat listrik"/”Beware
A
of electricity shock”
Exposed to the Respiratory Installing the sign of "Awas bahan kimia"/”Beware of
A
hazardous admixture disturbance hazardous chemical substances”
chemical The utilization of masks P
Inhale the cement’s Respiratory Install the sign of "Awas debu semen"/”beware of
A
dust disturbance cement’s dust”
The utilization of masks and goggles P
Strangulated hand Wound/injury Install the sign of "Awas terjepit"/”beware of being
A
strangulated”
The utilization of gloves P
Greasy floor Wound/injury Clean the greasy floor E
Install the sign "Awas licin"/”Beware of slippery floor” A
Casting
Strangulated by Wound/injury To cover the mold/to install it at the symmetrical A
molding straight position
A
Clean up the surface of mold’s edge from seplit and
stirring materials

Install the sign of "Awas terjepit"/”beware of being A

strangulated
The utilization of glove P
Run over by hopper Wound/injury Install the sign of "Awas tertabrak hopper"/”beware of A
run over by hopper
The utilization of safety shoes P
Run over by trolley’s Wound/injury The workers should be away from railway A
wheels Install the sign of "Awas trolly"/”Beware of trolley” A
The utilization of safety shoes P
Dirty hand by mortar Skin irritation The utilization of gloves P

The noise of Impact Hearing The utilization of earplug P

tool damage
Being exposed to Wound/injury
Other workers should be away from the range of
impact tool A
impact tool

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Potential Hazard Impact Controlling

The concrete compaction
Being exposed to the Skin irritation
The utilization of rubber safety shoes/boot, plastic
waste water P
glove and long-sleeved shirt
Hit by a throw Wound/injury
Installing the sign of "Awas bahaya lemparan ganjal
A
mur/baut"/”beware of the thrown of screw bolt”
The application of helmet P
Noise Hearing Installing the sign of "Gunakan tutup telinga"/”Please
A
damage use the earplug”
The utilization of earplug P

Steaming
Struck by Fatality The use of seling tool as capacity E
product/mold The routine maintenance of seling tool E
Operation that should fit IK E
Hoist operator should use SIO A
Installing the sign of "Awas seling hoist
A
putus"/”beware of broken seling hoist”
Slipped/fell down to Wound/injury
Installing the ladder inside the steam vessel E
steam vessel
Hot steam burst Burns
Wrapped and not leaking steam pipe E

Installing the sign of "Awas semburan uap

A
panas"/”Beware of hot steam burst”
Noise of Spinning Hearing Installing the sign of "Gunakan pelindung
A
damage telinga"/”Please use your earplug”
The application of earplug P
Opening the product
Struct down by Fatality The utility of seling as capacity E
products/molding The routine maintenance on seling tools E
The operation that fits IK standard E
Hoist operator should own SIO SIO A
Installing the sign of "Awas seling hoist
A
putus"/”beware of broken hoist seling”
Run over by trolley’s Wound/injury The workers should be away from railway A
wheel Installing the sign of "Awas trolly bergerak"/”beware
A
of moving trolley”
The utilization of safety shoes P
The cylinder Wound/injury APAR is available E
explosion (LPG and The correct setting of LPG/oxygen pressure A
oxygen)
Installing the sign of "Awas meledak"/”Beware of
A
explosion”
Sparks Wound/injury
The utilization of welding goggles/welding mask P
(blander/weld)

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Potential Hazard Impact Controlling

Struct by supporting Wound/injury
The utilization of use safety shoes P
tools
Inhale painting while Respiratory
labeling disturbance The utilization of should use mask P
Noise of Impact Tool Hearing Installing the sign of "Gunakan pelindung
damage telinga"/”Please use earplug” A
The Utilization of earplug P
Exposed by Impact Wound/Injury To clear the area of impact tools from other workers
A
Tools

Finishing
Electricity shock Wound/injury Installing the switch and plug-in E

Wrapped and not leaking electricity cable E

Sparks from grinding Wound/injury The utilization of mask and gloves P

machine The utilization of grinding goggles P
Fall down from Wound/injury Apply strong wood material for foothold E
ladder Use safety shoes
Sun burn Irritation The utilization of long-sleeved shirt P
The utilization of safety helmet P
Raining Sick During heavy rain, the activity is recommended to be
temporarily postponed A

During light rain, not too heavy, the utilization of P

raincoat is recommended

Stock Yard
Lack of light at night Uncomfortable Installing the SPOT HPIT lamp at line 1 E
Dehydration Skin irritation The utilization of long-sleeved shirt P
The utilization of helmet P
Struct by products Fatality Apply seling tools as capacity E

Routine and scheduled seling machine maintenance E

The operation should fit the IK E

Hoist operator should own SIO A
Installing the sign of "Awas seling hoist
A
putus"/”beware of broken hoist seling
Installing the sign of "Jangan berada di bawah dan di
atas benda yang diangkat"/”Do not stand under the A
lifted materials”
Strangulated by Wound/injury Concrete triangle wedge should be positioned on the
products products’ piling E

Gouge tools should be employed on the piling process E

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Annual Conference on Industrial and System Engineering (ACISE) 2019 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 598 (2019) 012123 doi:10.1088/1757-899X/598/1/012123

Potential Hazard Impact Controlling

The application of gloves P
Falling from the piles Wound/injury IK for piling process should be made A
Safety induction "Berhati-hati dalam bekerja"/”Be
A
careful while working”
During heavy rain, the activity is recommended to be
Rain Sick temporarily postponed A
During light rain, not too heavy, the raincoat is
P
recommended to be used
The making of pile shoes and the cover of power pole
Strangulated by mold Wound/injury The utilization of gloves P
Dirty hand by Skin irritation P
The utilization of gloves
concrete mixture

4. Conclusion
Total possible hazards are resumed as 53 possibilities. Set-up of reinforcement has 9 possible hazards,
followed by the stressing that has 4 potential hazards, the making of concrete has 6 potential hazards,
the casting with 6 potential hazards, the compaction of concrete has 3 potential hazards, the steaming
has 4 potential hazards, the opening of the product has 8 potential hazards, the finishing has 5 potential
hazards, followed by stock yard, which has 6 potential hazards. While the making of pile shoes and
power pole cover is identified with 2 potential hazards. The hazard potential level is measured 53% at
the high level with 28, 34% at the moderate level with 18 potential hazards, 11% at the extreme level
with 6 potential hazards and 2% at the low level with 1 potential hazard.
The controlling actions that should be performed are to maintain operation as IK (work instruction);
the maintenance of seling tools as its capacity; scheduled machine’s maintenance; signs’ installment;
The application of safety helmet, masks, earplug, safety shoes and gloves; the tools’ utility as their
capacity; to equip operators with SIO; the position of workers that should be away from the railway;
clean up the edge of mold from seplit and stirring materials; the position of workers that should be away
from the impact tool range; to install the ladder inside steam vessel; wrapping the steam pipe to avoid
leaks; to provide APAR; to set the pressure of oxygen/LPG; to install switch and plug-in; to maintain
wrapped electricity cable network to avoid the leaks; apply strong wood material for foothold; install
the SPOT HPIT lamp at line 1.

References

[1] Zou P X W and Sunindijo R Y 2013 Automat. Constr. 34 92-100.

[2] Haslam R A, Hide S A, Gibb A G, Gyi D E, Pavitt, Atkinson S and Duff A R 2005 Appl. Ergon.
36 401-15.
[3] Saedi A M, Thambirajah J J and Pariatamby A 2014 Safety. sci. 70 308-15.