Risk Factor Assessment in a Carpet Manufacturing Company Using the Failure Modes and Effects Analysis in Mazandaran

Abstract

Introduction and purpose: The most prevalent accidents and injuries occur in industries. Risk assessment and risk management are the basis for planning to provide solutions and control hazards. Therefore, the present study aimed to identify and assess the workplace hazards using the failure mode and effects analysis (FMEA) approach in a carpet manufacturing company located in Mazandaran. Methods: The current study utilized FMEA approach to evaluate the potential risk factors. Some units of carpet manufacturing company including 8 different workstations were assessed with 60 employees. Furthermore, failure modes and effects, as well as the causes of the failure of each component, were evaluated in this study. Subsequently, the Risk Priority Number of each workstation was separately calculated and the crisis level of each risk was prioritized. Results: According to the results of the study, out of 55 risk factors identified in 8 different workstations at the factory, 18.2 %, 67.3%, and 14.5% of these risk factors were within acceptable, unacceptable, and emergency level, respectively. Moreover, the units, including painting, dipping, extrusion, and assembly obtained the highest risk frequency in terms of explosion and electric shock. Conclusion: According to the results of this study, workers are highly susceptible to occupational accidents and injuries due to the presence of high risks factors in the above-mentioned unit. Although FMEA approach is applicable to identify the potential failures in work-related accidents, it is recommended using Preliminary Risk Assessment Method in order to conduct a more exact and comprehensive assessment.

Keywords

• Failure mode and effects analysis method
• Risk assessment
• Workrelated accident
• Workstation