Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Determination of hazard in truck manufacturing industry using hazard

identification risk assessment technique
R. Pawin vivid a,⇑, N. Selvakumar a, M. Ruvankumar b
a
Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, Tamilnadu, India
b
Deputy Manager-safety, Ashok Leyland, India

a r t i c l e i n f o a b s t r a c t

Article history: A lifting equipment plays an important role in assembly industries. In Truck manufacturing plant, assem-
Received 21 March 2020 bling components of truck chassis involves many numbers of process and then loading of components in
Received in revised form 28 March 2020 the finishing process creates problems for workers. This study is to identify the potential risk in assem-
Accepted 1 April 2020
bling process at the industry by using hazard identification Risk Assessment (HIRA). The appropriate risk
Available online xxxx
controls are providing engineering controls, administrative controls and personal protective equipment.
This HIRA study may help to employer be more proactive in ensuring the safety and health of workers.
Keywords:
The hazard has been identified and evaluated, then possible control measures will be recommended
Risk
Safety
for safe execution of activities.
Hazard Ó 2020 Elsevier Ltd. All rights reserved.
Truck assembly line Selection and peer-review under responsibility of the scientific committee of the First International
Control measures conference on Advanced Lightweight Materials and Structures.

1. Introduction be effectively evaluated using Hazard Identification and Risk

Trucks are manufactured in the form of light-duty, medium-
duty and heavy-duty classifications depending on their chassis
weight. The heavy-duty truck chassis has a gross weight of 16 tons.
The trucks move along an assembly line as various components are
assembled by different stage workers. The HIRA is a systematic
method of identifying and preventing assembly process problems
before they occur. HIRA’s are focused on preventing unsafe act
and condition impact, enhancing safety, component defects and
increasing customer satisfaction. Ideally, HIRA is conducted in
the process stage, although conducting a HIRA on existing control
measures can also yield substantial benefits [1]. The truck chassis
started with a frame assembly; it acts as the backbone of the truck.
Assembling the components of truck chassis involves many pro-
cesses. From loading of the components into the frame assembly
to the finishing process of the final truck involves various safety
risks for the workers. These risks may happen due to hazards like
lifting equipment, pneumatic guns, cranes, materials handling, tor-
que machines and conveyor. These risks are also dangerous to
work environment. The hazards in the automobile industries can
⇑ Corresponding author.
E-mail addresses: pawin503@gmail.com (R. Pawin vivid), nselva@mepcoeng.ac.
in (N. Selvakumar).
Assessment [2]. In this paper Hazard Identification and Risk
(Fig. 1) Assessment study were performed on the various levels
of the process in assembling line of the truck manufacturing plant.
This study may help in preventing and reducing exposure of risk to
the employee in the assembly line (Fig. 2).
The HIRA is used to identify and analysed, all potential failure
mode of different process of the system, effects of these failure
mode on the system and how to prevent the potential failure
modes and moderate the effect of the failure system [3]. HIRA is
a step by step wise to identifying all possible potential failure
mode throughout the processes. Applied HIRA technique on foun-
dry industry and prevent different potential failure mode and sug-
gestions were successfully implemented and the industry gained
considerably in terms of both money and time [4]. Used HIRA, hier-
archy process method to minimize the safety deviations in new
process development in various automobile industry [5].
Importing of several components from the outside industries
faces several problems like uncertainties in environmental factors
and logistics problem. Trade within industry also faces in logistics
problem according to act. To rectify this problem, several hazard
evaluation tool can be used and these risk assessment technique
like spas are used to identify the level of risk associated with each
failure modes that are identified from the risk of various compo-
nents assemble process result obtain from the analyses show the

https://doi.org/10.1016/j.matpr.2020.04.006
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the First International conference on Advanced Lightweight Materials and Structures.

Please cite this article as: R. Pawin vivid, N. Selvakumar and M. Ruvankumar, Determination of hazard in truck manufacturing industry using hazard iden-
tification risk assessment technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.04.006
2 R. Pawin vivid et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 1. Production process.

1.1. Production process

The objective of this paper is to study HIRA and evaluate the

hazards, risk and also to provide control measures for the safe exe-
cution of activities. To identify and enhance assembly line to
reduce or eliminate the potential hazards. To Suggest additional
control measures to reduce the risk to acceptable level. To improve
safety, reliability. To reduce more of the criteria that make up the
RISK PRIORITY NUMBER (RPN).

2. Methodology

By visiting the plant, four to five days observed the various

stage workers activities. Walking around the assembly line to
Fig. 2. Methodology.
inspect the general area. Various stages and material’s handling
in the assembly line noted. To study, Standard Operating Procedure
(SOP) after to interacted with workers to list out their difficulties.
Looking at literature review, detailed study of HIRA to performed
critical level [6]. So, we can avoid potential risks by knowing these
in various industry process. A HIRA study is a formal systematic
critical levels. So, it is important to improve safe work
procedure used to review the existing control measures and oper-
environments.
ation of a potentially hazardous process facility. It is used to iden-
While considering the automobile manufacturing industry in
tify deviations from normal safe operation, which could lead, to
India, it as a steady growth among the industry sector. Although
hazards (or) unsafe condition, potential failure modes and to define
automobile industries are growing faster, it too has some associ-
any actions necessary to deal with these. To obtain process in the
ated with it. These risks may happen due to hazards like lifting
various stages were analyzed and identified the hazards. The dis-
equipment, pneumatic guns, cranes, materials handling and torque
cussion was conducted with the maintenance team to recom-
machines and conveyor [8]. These risks are also dangerous to work
mended possible control measures.
environmental. So, safety in the assembly process is more impor-
tant. These safety measures can be done several methods, risk
assessment, safety models. These steps have been implemented 3. Hazard
to reduced several injuries and accidents still happening [9]. A
‘‘Effect Analysis” denotes to studying the consequences of those Hazard is defined as potential to cause injury or illness to
failures in oil refinery process [10]. humans, property damage, and pollution to the environmental.

Please cite this article as: R. Pawin vivid, N. Selvakumar and M. Ruvankumar, Determination of hazard in truck manufacturing industry using hazard iden-
tification risk assessment technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.04.006
 R. Pawin vivid et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

The hazards are classified as, potential hazards and illness hazard. 4.5. HiRA procedure
Hazard is defined as a process (or) plant that represents unsafe
condition causes of potential accidents [7]. An accident in this term Following step has been followed for HIRA implementation
defined as an unexpected event during improper activity. The
effect of accident loss of life, permanent disability body parts, loss Step 1: Study plant process (or) the functions of system.
of property, loss of production and environmental. The hazard
evaluation tools and risk assessment techniques are providing mit-
igate measures and also planned. Table 1
Exposure Table.

4. HiRA value severity effect

1 There is no injury, property damage above Rs 5,000
HIRA is an analytical technique that combines technology and 2 There is minor injury, property damage less than Rs 25,000
experience of worker (or) supervisors in identifying probable 3 There is serious injury, property damage above Rs 50,000
4 There is major injury, property damage above Rs 1,00,000
potential failure mode of process and planning for its abolition. 5 There is fatal, property damage above Rs 5,00,000
HIRA is a ‘‘before-the-event” action requiring a team (Safety, Main-
tenance, Production) effort to easily and inexpensively alleviate
changes in production process. This risk assessment method used
to manage safety risks. The hazard has been identified and evalu-
ated; then possible control measures will be recommended for safe Table 2
execution of activities. It is a continuous developing technique. It Severity table notation.
should be avoided unsafe operation and provide safe execution VALUE SEVERITY EFFECT
procedure.
1 There is no injury, property damage above Rs 5000
RISK PRIORITY NUMBER ¼ Severity  Probability 2 There is minor injury, property damage less than Rs 25,000
3 There is serious injury, property damage above Rs 50,000
 Exposure 4 There is major injury, property damage above Rs 1,00,000
5 There is fatal, property damage above Rs 5,00,000

4.1. Hazard identification

The observations had been carried out during working assembly

Table 3
line to identify the hazard and exposure through the flow of mate- Probability table notation.
rial handling, lifting equipment’s, cranes, pneumatic guns, torque
VALUE LEVEL DESCRIPTION
machines and conveyor involving the assembling process, the
worker work patterns and deviations or working environment. 5 Very Has happened once during last one year in theDivision
high
During the observations in the assembly line, employees were
4 High Has happened in the Division or once during lastone year
interacted to obtain information related to the identification of in Company
hazard that have occurred and that may occur. One of the hazards 3 Medium Has happened in the Company
is the mechanical hazard, such as hit or fall due to the overhead 2 Low Happened in the Power Industries globally duringlast
lifting equipment’s in the assembly line. The range of equipment 20 years.
1 Very Happened in the Industries globally during last 10years.
that can be found in the assembly line consist of the pressing low
machines, cranes, lifting equipment’s, pneumatic guns, torque
machines and conveyor.

4.2. Engineering controls

Table 4
Risk Evolution Matrix.
Engineering controls are to eliminate (or) minimize the hazards.
The substitution of alternative equipment (or) process procedure
to decrease the hazards is to be adopted. Isolation of the hazard
with interlock mechanisms, machine guards, shields.

4.3. Administrative controls

Document (or) written format standard operating procedures,

work permits, and safe work practices. These control measures
are mostly used to reduce noise, heat stress and ergonomic haz-
ards. It provides alarm systems, safety signs, warnings, and
training.

4.4. PpE

Personal protective equipment (PPE) and it creates a barrier

against workplace hazards. PPE is acceptable as a control method
in following when engineering controls are don’t eliminate the
hazards. During an emergency when engineering controls may
not be activated.

Please cite this article as: R. Pawin vivid, N. Selvakumar and M. Ruvankumar, Determination of hazard in truck manufacturing industry using hazard iden-
tification risk assessment technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.04.006
 Table5

4
tification risk assessment technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.04.006
Please cite this article as: R. Pawin vivid, N. Selvakumar and M. Ruvankumar, Determination of hazard in truck manufacturing industry using hazard iden-

HIRA of Truck Chassis Assembly Line.

5.10 HAZARD IDENTIFICATION AND RISK ASSESSMENT OF TRUCK CHASSIS ASSEMBLY LINE
HAZARDS IDENTIFIED WHAT IS THE RISK WHAT IS THE WHAT IS THE HOW MANY RPN IS IT - CONTROL MESURES
ASSOCIATED WITH THE SEVERITY OF THE PROBABILITY/ PEOPLE ARE LOW,
ENGINNEING CONTROL ADMINISTRATIVE PPE
HAZARD?(Injury, Ill RISK?(If S is ‘‘500 LIKELIHOOD OF LIKELY TO BE MEDIUM,
CONTROL
health, Loss of life, it is ”Urgent‘‘ & THE EXPOSED OR HIGH,
Property Damage,Fire Intolerable) OCCURRENCE OF AFFECTED?(Enter URGENT?
Explosion) THE RISK? the rating only)
Holder slippage while moving the Injury 4 2 2 16 H Modification of holding pin,
assembly Fencing the machine.
Accidental slip of leaf spring while Injury 3 3 2 18 H 1. Tackle modified for lifting leaf
loading spring (PEP) Completed2. Rear and
front axle spring crane colliding
with each other. Rail and crane
modifications required.
Axle slip and fall off trolley while Property damage 3 3 2 18 H Tackle design to be modified to
loading increase area of contact to avoid

R. Pawin vivid et al. / Materials Today: Proceedings xxx (xxxx) xxx

Accidental slip of hook and hit against
person
Frame slip and fall off from trolley
while loading
Exposure to Noise
Frame slip if multi spindle not released
from frame
Partial clamping of cylinder mouth
side leads to cylinder falling down
Hand / fingers caught while expanding
Air hoses lying on the floor hinders
operator movement
Accidental slip of torsion bar while
loading
Fatal (or)Injury to workers due to
chassis turn-over process during
fixture taken and replacing.
Operator will go suspended the
chassis, do the fixture taken and
replacing.
Cabin slip and fall off from frame while
mounting
Manual mounting of tyre in case of
failure of machine
axle falling down.
Injury 3 3 2 18 H Not standardized tackle (welded
hook) used for lifting front and rear
axle. Shall be checked and certified
for loading capacity periodically.
Injury & Property damage 3 3 2 18 H Limit switch to be installed on the
VIN marking machine rail.
Injury 2 5 2 20 H Noise mapping Job rotation
practiced shall be
follow.
Injury 3 3 2 18 H Crane colliding with each other.
Rail and crane modifications
required.
Injury & Property damage 4 3 2 24 H Automatic crane operation (turn
over operation) and evacuation on
the stage to be verified
Injury 3 3 2 18 H Rope to be monitored for lifetime
and weariness of the belt.
Injury 3 3 2 18 H Air hose hung over stand shall be
install.
Injury 3 3 2 18 H Training to be
provided for the
new operators
before deploying
in the stage
Injury, Loss of life & 5 5 2 50 U Design and fabrication of fixture
Property damage replacing equipment
Injury & Property damage 3 3 2 18 H Only authorized
person operates
the crane.
Injury 3 3 2 18 H Portable tyre mounting trolley to
be fabricated as a contingency
method
 R. Pawin vivid et al. / Materials Today: Proceedings xxx (xxxx) xxx
Step 2: Determine the hazards of each component and its
effects. Assign the severity rating (S) according to the respective
effects on the system based up on the severity table.
Step 3: Determine the causes of hazards (or) potential failure
modes and estimate the likelihood of each potential failure
occurring. Assign the probability rating (P) of each hazard
according to the respective effects on the system based up on
the severity table.
Step 4: List the number of worker exposure and evaluate the
ability of system to affect the workers to the potential failures
occurring. Assign the exposure rating (E) of each hazard.
Step 5: Calculate the risk priority number (RPN).
Step 6: Provide control measures (Engineering, Administrative,
PPE) to enrich the performance of system.
Step 7: Conduct HIRA report in a tabular form.
Step 8: Implementation follow and System review.
4.6. Exposure table
Notations (osh-ms 1722:2003)
An example for exposure rating shown in Table 1
4.7. Severity table
Severity, this term represents as assessment of seriousness of
the potential failure impact. In this we have to determine all poten-
tial failure modes based on the process requirements and their
effects. Table 2 shows an example of severity is given below.
4.8. Probability table
Determination of probability, it is necessary to look at the cause
of a potential failure due to accidents and how many times it
occurs. An example for probability rating is given in following
Table 3.
4.9. Risk evolution matrix
Table 4 shows an example for risk assessment evolution matrix.
5. Result and discussion
By visiting the plant, various process stages in the assembly
lines were observed and interacted with workers to list out their
difficulties. In this study focused on lifting equipment, instrumen-
tation, utilities, routine and non-routine human actions, and exter-
nal factors, materials handling that might impact a process the
human factors such as workplace injuries, illness and increase
morale. The legal factors are meeting legislative requirements,
occupational Health and Safety and Workcover and also financial
factors, reduce absenteeism, increase potential for gaining share-
holders and increase productivity, these factors are considered.
The assembling process in the various stages were analysed and
identified the hazards and then values are assigned to Tables 1-4
low, medium, high to determine the RPN number. The hazard that
have been identified were assessed using hazard Identification Risk
Assessment Form as shown in Table 5. With the determined RPN
number, values above 15 immediate action to be taken. RPN 15
above the value high risk is not acceptable. Further detailed study
should be performed to give a better estimate of the risk. If this
analysis risk matrix RPN value still shows unacceptable or medium
Please cite this article as: R. Pawin vivid, N. Selvakumar and M. Ruvankumar, Determination of hazard in truck manufacturing industry using hazard iden-
tification risk assessment technique, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.04.006
5
risk redesign or other changes should be introduced to reduce the
possibility of potential accidents.
The discussion was conducted with the maintenance team to
provide suitable and possible control measures Table 5. The result
shows that the fetal accident into manually fixture replacing pro-
cess was the most critical hazard. Fixture replacing process can
be categorized as local workplace risk factor. Then possible control
measures will be recommended for safe execution of activities. The
purpose of the HIRA, to identify those accidental events that should
be subject to a further, and more detailed risk analysis.
6. Conclusion
In Truck manufacturing plant, HIRA is a systematic approach to
the review of existing control measures, analysis, definition, esti-
mation, and evaluation of risks. The HIRA has been carried out,
thus identified the hazards and risk by analysing each step
involved in various processes in the assembly line. These risks
may happen due to hazards impended in equipment involved in
the assembling line process. Possible modes of potential failure
of an assembly line process have been identified, the severity,
exposure and probability of these potential failures’ modes are uti-
lized in quantify the RPN. Also, the possible control measures for
identified hazards are recommended for safe execution of activi-
ties. HIRA analysis may easily help in improving the efficiency of
the assembling process and quality of product thus decreasing
the number of accidents, defective products and saving of rework
cost and time. Recommended other hazard tools are also can be
used to analyse the hazard such as Job Safety Analysis (JSA), check
list for improving worker safety.
CRediT authorship contribution statement
R. Pawin vivid: Conceptualization, Methodology, Writing -
original draft. N. Selvakumar: Supervision. M. Ruvankumar: Data
curation, Visualization, Investigation.
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