Risk Identification and Risk Assessment Using Failure Mode and Effect Analysis in a Textile Industry

Abstract

Background: Today with growth of industry, occupational hazards are increasing proportionally. One of the most important parts of these industries are human resources, which face with many various hazards. The aim of this study was to conduct an assessment of potential hazards in the textile industry using Failure Mode and Effect Analysis (FMEA). Methods: This cross-sectional study was conducted in the spinning sector of textile industry. FMEA as one of the systematic risk assessment technique applied to each unit of the spinning sector to find out potential failure mods and its effects. Risk priority number (RPN) was determined based on severity, detectability and occurrence of hazards. Then PRN were categorized into low-risk (RPN ≤ 89), moderate risk (RPN = 90-199), and high risk level (RPN ≥ 200). Results: A total of 58 risk were found in 6 units of the spinning sector. 38% were found to be at high level 45% at middle level and 17% at low level. The packing unit, had the highest risk compared to other units. Lifting heavy loud in the packing unit has the highest RPN (384) and bobbin falling down in the ring unit has the lowest RPN (24). Conclusion: This study revealed that more than 80% of detected risk were unacceptable that showed hazardous condition for workers in textile industry. Lifting heavy louds followed by bobbing falling were the most hazardous task in this industry. The implementation of safety measures such as training programs, engineering and management controls were recommended.