Risk Factors Assessment in Educational Equipment Manufacturers Company Using FMEA

Introduction and Industrial accidents are highly prevalent. Regarding this, identification of the risk factors of occupational accidents can be helpful in preventing the occurrence of this type of accidents. The aim of this study was to assess the risk factors in the incidence of occupational accidents and prioritize the severity of the identified risks in order to prevent their occurrence.
The current study utilized failure mode effects analysis (FMEA) method to evaluate the potential risk factors. All the units of Educational Equipment Manufacturers Company, including 12 different workstations with 55 employees, were assessed; furthermore, failure modes and effects as well as the causes of the failure of each component were recorded. Subsequently, Risk Priority Number (RPN) of each workstation was separately calculated and the crisis level of each risk was prioritized.
According to the results of the study, a variety of 51 risk factors were identified among 12 different workstations at the factory. It was demonstrated that 4.25%, 9.54%, and 6.19% of these risk factors were within acceptable, unacceptable, and emergency level, respectively. The highest risk frequency was related to the electric shock caused by working on guillotine, cutter, bending machine, and drilling press. However, the crisis level of these risk factors were found to be average owing to the decrease in the occurrence of these risk factors which was the result of control measures.
This study revealed a direct relationship between RPN and the frequency of occupational accidents. Because of the high risks of the aforementioned machines, plant workers are highly prone to occupational accidents and injuries. Although FMEA method is a functional approach in determining the risks of occupational accidents, it is also recommended to use process hazard analysis in order to have a more precise and comprehensive assessment.