The Multi-Attribute Failure Mode Analysis to Reduce Work Accident in a Metal Fabrication Company

Abstract

Metal manufacturing companies attempt to increase its productivity by streamlining the processes. However, hazards may occur. Many accidents occurred ranging from minor to severe. In designing the occupational safety and health (OSH) management system, knowledge of risk management is very important because risk management can identify risks, assess risks, and reduce risks to a reasonable extent. This study aims to identify the risk of work accidents, then classifies the risks of work accidents based on the most significant impacts and finally provides recommendations for improvements to overcome the risks of work accidents with the most significant impact. A studied case was conducted in metal fabrication company. The Failure Mode and Effect Analysis (FMEA) integrated with Analytic Hierarchy Process (AHP), i.e., the Multi-Attribute Failure Mode Analysis (MAFMA) was deployed. The results obtained in this study indicate that 14 work accident risk events have occurred and have been validated by the company. The risk classification of work accidents using the MAFMA method produces a risk value weight in decimal numbers, sorted from highest to lowest, to be included in the Pareto diagram. Based on the results of the Pareto diagram with the 80/20 principle, the events that were the researcher's focus were given three improvement proposals; namely, the hands were crushed by the blade, the head hit the top slides, and slipped. Recommendations for improvement proposals are focused on two events with the highest MAFMA score to be given a proposed improvement. Proposals that can be given include requiring workers to wear personal protective equipment (PPE) in production, adequate lighting, making work instructions, paying attention to work procedures, and paying attention to the machine's condition.