7B1-4 2016 2nd International Conference of Industrial, Mechanical,

Electrical, Chemical Engineering (ICIMECE)

Analysis of Potential Work Accidents Using Hazard

Identification, Risk Assessment and Risk Control
(HIRARC) Method
Bambang Suhardi Andhika Ayu Valentina Estianto Pringgo Widyo Laksono
Department of Industrial Engineering Department of Industrial Engineering Department of Industrial Engineering
Faculty of Engineering, Sebelas Maret Faculty of Engineering, Sebelas Maret Faculty of Engineering, Sebelas Maret
University University University
Surakarta, Indonesia Surakarta, Indonesia Surakarta, Indonesia
bambangsuhardi_ugm@yahoo.co.id andhika.ave@gmail.com pringgo@ft.uns.ac.id

Abstract— Batik Merak Manis Laweyan is one of the batik
industry in Surakarta, where in the production process there are
the potential accidents. The company also has provided personal
protective equipment to workers to minimize the risk, but in
reality, not all workers use personal protective equipment. The
purpose of this study was to analyze the potential hazards that
may occur and determine root causes of the occurrence so as to
minimize the number of occupational accidents. This research
uses the method of Hazard Identification, Risk Assessment and
Risk Control (HIRARC) in analyzing potential hazards that may
occur in the workplace by identifying hazards, risk assessment,
and rank the risks. The risks that have the highest ratings will
then be analyzed using the method of Fault Tree Analysis to find
out the root cause of the occurrence. The results showed that
there were 15 potential hazards, where two potential hazards
have a high-risk level, 6 potential hazards have a medium risk
level and 7 potential hazards have a low-risk level. Two potential
hazards with high risk, it is known that factors causing potential
hazards are a factor of dye used, the use of personal protective
equipment such as masks, or the space factor of production.
Keywords—hazard, risk, hirarc, fault tree analysis, work
accident, occupational health and safety
I. INTRODUCTION
Batik has now become a necessity for the people of
Indonesia [1]. Batik producer, particularly in this study is
Batik Merak Manis Laweyan, trying to increase production to
satisfy consumer needs. In the production process cannot be
separated from the labor factor must also be considered, by
guaranteeing health and safety and prevent accidents.
Occupational health and safety is an attempt and thought to
guarantee the integrity and perfection of both physical as well
as spiritual human beings in General and of labor in particular,
along with the results of his work in the community toward a
just, prosperous and peace [2]. Occupational safety and health
is important to protect labor or others in the workplace [3] of
the work accident and avoid large losses for the company.
Work accident is an event that is clearly undesirable and often
unpredictable again, which can cause loss of a good time,
possessions or property or loss of life that occurred in a work
process industry or related to it [2]. Therefore, as far as
possible work accidents are minimized in order to make the
whole process run smoothly and the safety of workers is
protected.
The company has tried to provide personal protective
equipment to workers for the safety and health of workers. But
in reality, not all workers use personal protective equipment,
so that workers are still potentially a work accident.
Based on early observations, there are some potential
hazards that exist in the workplace Batik Merak Manis
Laweyan. For example, there are puddles around the dyeing
tub that can harm workers who pass it if not walk carefully.
The risk that may occur is the worker slipped because of the
slippery floor. In addition, there are also a harmful chemical
substances that are used during the production process which,
if inhaled by workers can interfere with the health of the
workers.
Based on interviews with workers, some accident they've
ever experienced slipped because of the slippery floor, feet
and hands are itching due to exposed to chemical substances
during the process of dyeing color, breathing difficulty during
the process of washing fabric, as well as a foot wedged the
wheel trolley fabric.
Based on the description of these problems, then need to
do research to find out the potential for accidents that may
occur in the Batik Merak Manis Laweyan, particularly in the
batik printing station and look for the root cause, so can
improve occupational health and safety. Batik printing station
became the focus of the research by considering the number of
orders against the kind of production that is 4000 items per
day compared with the production of batik stamp 800 items
per day and the production of batik handmade is 20 items per
day. So workers at the batik printing station work
continuously for 6 working days (8 hours per day) to meet all
orders from consumers. Thereby, the workers have a greater

978-1-5090-4161-9/16/$31.00 ©2016 IEEE 196

7B1-4 2016 2nd International Conference of Industrial, Mechanical,
Electrical, Chemical Engineering (ICIMECE)

risk of exposure to the chemical substances used in the unusual

production process. Conceivable Might occur at some time in the future 3
Remote Has not been known to occur after many 2
The methods used to analyze the potential of a work years
accident, namely Hazard Identification, Risk Assessment and Inconceivable Is practically impossible and has never 1
Risk Control (HIRARC). HIRARC is a series of processes to occurred
identify hazards that may occur in the company's activities, Source: DOSH Malaysia (2008)
assess the risk of these hazards and make the control of TABLE II. SEVERITY OF HAZARD
hazards to minimize the risk to a lower level with the aim of
Severity Description Rating
preventing accidents [4]. HIRARC is divided into four steps, Catastrophic Numerous fatalities and irrecoverable 5
i.e classifies types of work, identifying the types of hazards, property damage
conduct a risk assessment and determine the risk rating [5]. Fatal Approximately one single fatality/major 4
While the root causes of those risks are analyzed using the property damage if hazard is
realised
method of Fault Tree Analysis (FTA). The FTA method is
Serious Non-fatal injury, permanent disability 3
used because this method is effective in finding the core issue Minor Disabling but not permanent injury 2
as it ensures that an event of unwanted or harmful does not Negligible Minor abrasions, bruises, cuts, first aid type 1
originate from a single point of failure. This method also injury
identifies the relationship between the factors shown in the Source: DOSH Malaysia (2008)
tree causes the error associated with a simple logic gate [6]. According to the table above, the risk can be calculated
The purpose of this research is to analyze the potential using the following formula:
hazard that may occur and find the root cause of the
occurrence. Risk = likelihood x severity (1)

II. METHODOLOGY 3) Determining the level of risk: this step done to find out
any risk that requires immediate treatment based on the risk
Research methodology includes the following stage of assessment. This determination was based on the risk
observation, stage of analysis of HIRARC which consists of
assessment matrix is divided into 3 categories, there are low
the identification of hazards, risk assessment, and
risk, medium risk and high risk. Here is the matrix of risk
determination of the ranking of risks and the stage of Fault
assessment:
Tree Analysis.
A. Observation TABLE III. RISK ASSESSMENT MATRIX
This is the observation stage of the research object directly
and thoroughly. The purpose of this stage is to find out the real Severity
Likelihood
1 2 3 4 5
conditions of the research object. 5 5 10 15 20 25
1) Interview with stakeholders: this stage is done to get an Medium Medium High High High
overview and information about the situation in Batik Merak 4 4 8 12 16 20
Manis Laweyan. Low Medium Medium High High
3 3 6 9 12 15
2) Interview with workers: this stage is done to find out Low Medium Medium Medium High
occupational accidents experienced by workers and the health 2 2 4 6 8 10
complaints experienced by workers. Low Rendah Medium Medium Medium
1 1 2 3 4 5
3) Identification of batik printing production process: this Low Low Low Low Medium
stage is conducted to understand the steps or the production Source: DOSH Malaysia (2008)
process of batik printing in Batik Merak Manis Laweyan.
C. Fault Tree Analysis: this stage done to find out the root
B. HIRARC Analysis
cause of a risk that requires immediate treatment.
HIRARC analysis consists of hazard identification, risk
assessment and determination of risk rating. III. RESULT AND DISCUSSION
1) Hazard Identification: this stage of hazard identification
The result of this study is potential hazards and risks that
based on the production process of batik printing.
2) Risk Assessment: this stage done a risk assessment may occur in Batik Merak Manis Laweyan, a risk assessment
based on likelihood of risk occurrence and severity of the risk. of each potential hazard, the determination of the risk level of
Here is the table of likelihood and severity of the risk: priority and the root causes of risk priority.

TABLE I. LIKELIHOOD OF AN OCCURRENCE A. Hazard Identification

Likelihood Description Rating
Based on the production process in the fabrication of batik
Most Likely The most likely result of the hazard/event 5 printing, the potential hazards can be seen in the following
being realized table:
Possible Has a good chance of occurring and is not 4

197
7B1-4 2016 2nd International Conference of Industrial, Mechanical,
Electrical, Chemical Engineering (ICIMECE)
TABLE IV. HAZARD IDENTIFICATION
8 Worker - The worker’s Screen
No Potential Picture Risk Source of grazed a foot injured plangkan
Hazard Hazard part of placed
1 Worker - Foot dislocate Slippery screen anywhere
slip - Fracture floor plangkan
- Paralyzed

No Potential Picture Risk Source of

Hazard Hazard
2 The - The skin Dye
hands of become
worker reddened, No Potential Picture Risk Source of
exposed itching, and Hazard Hazard
to dyes irritation 9 The - The skin Dye
worker’s become
foot reddened,
exposed to itching, and
dyes irritation
3 Worker - The head of the The
stumbled workers hit the object
table or floor around
10 Worker - Inflammation Dye
- Workers the print
inhaling of the
exposed to dyes table
dyes in the respiratory
that spilled on dye mixing tract with
the floor which process symptoms of
can cause cough,
irritation and breathing
itching of the difficulty,
skin fever
4 Worker - The skin Hot
exposed become steam
to the hot reddened, may from the 11 Worker - Inflammation Steam
steam also cause sore steaming breathing of the dye
on the skin and chamber difficulty respiratory
eyes smell of tract
steam dye
during
washing
fabrics
5 The head - Head bruised Steaming
of the chamber 12 The - Hand injured Hook on
worker door is worker’s and bleeding “jagrak
hitted a lower hand grazed steam”
part of than the hook on
steaming height of “jagrak
chamber the steam”
average
worker 13 Worker - Worker Tempera-
works in become ture of
6 The head - Head bruised The part the hot exhaustion the room
of the of dryer room
worker machine - Dehydration
(33oC)
hitted a is lower - Loss of
part of than the concentration,
dryer height of so often make
machine the mistakes
average 14 Dangerous - Low back The
worker work pain equipt-
posture - Musculo- ment is
skeletal poor
7 Worker - Worker injured, The disorder
fallen wounded or position
from the bruishing of the
print worker
table on print
table

198
7B1-4 2016 2nd International Conference of Industrial, Mechanical,
Electrical, Chemical Engineering (ICIMECE)

15 Work - Pain in the Work running

activities feet activities continously
done by - faique with
standing standing C. The Determination of The Risk Level
and running and
continously running
This stage is done to determine the risk priority requiring
continous immediate treatment. The following table is a table of risk
ly rating of the high risk to lower risk.

TABLE VI. RISK RATING

No Potential Hazard Level of Risk
B. Risk Assessment 1 Worker slip High
Based on the identification of hazard that have been done 2 The hands of worker exposed to dyes High
3 Worker stumbled Medium
before, then do a risk assessment using formula (1). The result
4 Worker exposed to the hot steam Medium
of risk assessment can be seen in the following table: 5 The head of the worker hitted a part of steaming Medium
TABLE V. RISK ASSESSMENT chamber
6 The head of the worker hitted a part of dryer Medium
No Potential Likeli- Severity Number Level of machine
Hazard hood of Risk Risk 7 Worker fallen from the print table Medium
1 Worker slip 5 2 10 Medium
8 Worker grazed a part of screen plangkan Medium
2 The hands of 5 2 10 Medium
9 The worker’s foot exposed to dyes Low
worker exposed
to dyes 10 Worker inhaling dyes in the dye mixing process Low
3 Worker 4 1 4 Low 11 Worker breathing difficulty smell of steam dye Low
stumbled during washing fabrics
4 Worker exposed 5 2 10 Medium Low
12 The worker’s hand grazed hook on “jagrak steam”
to the hot steam
13 Worker works in the hot room (33oC) Low
5 The head of the 4 1 4 Low
worker hitted a 14 Dangerous work posture Low
part of steaming 15 Work activities done by standing and running Low
chamber continously
6 The head of the 4 1 4 Low
worker hitted a
part of dryer D. Fault Tree Analysis of Risk Priority
machine
7 Worker fallen 4 1 4 Low Fault Tree Analysis is done on a risk priority to find root
from the print causes of the accident. It is expected the company to pay more
table attention to these factors so as to prevent accidents.
8 Worker grazed 4 1 4 Low
a part of screen
Based on the risk rating, there are two potential hazards
plangkan with high risk, was obtained that the potential hazard at high
9 The worker’s 5 2 10 Medium risk are two potentials, there are worker inhaling dyes in dye
foot exposed to mixing process and worker breathing difficulty smell of steam
dyes dye during washing fabrics. Fault Tree Analysis of potential
10 Worker inhaling 5 3 15 High
worker inhaling dyes in dye mixing process can be seen as
dyes in the dye
mixing process follows:
11 Worker 5 3 15 High
breathing
difficulty smell
of steam dye
during washing
fabrics
12 The worker’s 4 1 4 Low
hand grazed
hook on “jagrak
steam”
13 Worker works 4 1 4 Low
in the hot room
(33oC)
14 Dangerous 5 2 10 Medium
work posture
15 Work activities 5 2 10 Medium
done by
Fig. 1. Fault Tree Analysis of potential worker inhaling dyes in dye mixing
standing and
process

199
7B1-4
Fig. 1. Indicates that on potential worker inhaling dyes in
dye mixing process is caused by several factors, among others:
dyes that are used in powder form fluttering in the dye mixing
process; the workers did not use a mask because the workers
are not accustomed to use a mask because it found difficult to
breathe or feel swelter, the mask is not available because there
is no request from workers or companies do not care.
While the Fault Tree Analysis of potential of worker
breathing difficulty smell of steam dye during washing fabrics
is as follows:
Fig. 2. Fault Tree Analysis on potential worker breathing difficulty smell of
steam dye during washing fabrics
Fig. 2. shows that on a potential of worker breathing
difficulty smell of steam dye during washing fabrics caused by
the temperature factor of the room is hot or worker did not use
a mask. The heat factor due to its small production room or
less air circulation. While the workers did not use a mask
because workers are not accustomed to use it or a mask is not
available. Workers are not accustomed to use a mask because
workers found it difficult to breathe or workers feel swelter.
While the mask is not available is caused by no request from
the worker or companies do not care.
IV. CONCLUSION
The conclusion of this research that there are 15 potential
hazards that exist in Batik Merak Manis Laweyan, two
potential hazards at high risk, 6 potential hazards with medium
risk and 7 the potential hazard at low risk. Two potential
hazards with high risk, it is known that factors causing
potential hazards are a factor of dye used, the use of personal
protective equipment such as masks, or the space factor of
production. It may be a consideration for companies to make
improvements so that the risks posed can be minimized so that
the health and safety of workers are protected.
2016 2nd International Conference of Industrial, Mechanical,
Electrical, Chemical Engineering (ICIMECE)
REFERENCE
[1] C. Wildainy and Y. Y. Sunarya, “The Aplication of Batik Garut Mojang
Priangan in Organza for Ready to Wear Clothing”, Journal of Art and
Design , 1, 2014.
[2] Tarwaka,”Occupational Health and Safety 'Management and
Implementation K3 in the Workplace'” 2nd ed, Surakarta: Harapan
Press, 2014.
[3] E. Sulistyoko, “Analysis of the Implementation of Work Safety in
Enterprises Improve Work Productivity Approach Fault Tree Analysis
(Case Study: PT. Permata 7, Wonogiri)”, Library of UMS, 2008.
[4] M. F. Socrates, “Safety Risk Analysis using Method of HIRARC
(Hazard Identification, Risk Assessment and Risk Control) on the Tools
Suspension Preheater the Plant Production Section 6 and 11 Field
Initiative”, Bachelor thesis of S-1 of Universitas Islam Negeri Syarif
Hidayatullah, 2013.
[5] Suma’mur, “Work Safety and Accident Prevention”, Jakarta: PT. Toko
Gunung Agung, 1986.
[6] K. R. A. Roehan, Yuniar, and A. Desrianty, “Proposed Improvement
Safety and Health Management System (SMK3) Method Using Hazard
Identification and Risk Assessment (HIRA). Online Journal of Institut
Teknologi Nasional, 2, 2014.
[7] Anizar,“Technique of Safety and Health at Work in Industry”,
Yogyakarta: Graha Ilmu, 2012.
[8] A. P. Mangkunegara, “Human Resource Management Company”,
Bandung: PT. Remaja Rosda Karya, 2002.
[9] A. Wijaya, T. W. S. Panjaitan, and H. C. Palit, ”Health and Safety
Evaluation using Method of HIRARC at PT. Charoen Pokphand
Indonesia”, Titra Journal, 3, 29-34, 2015.
[10] DOSH Malaysia, “Guidelines for Hazard Identification, Risk
Assessment and Risk Control (HIRARC)”, Malaysia: Department of
Occupational Safety and Health, 2008.
[11] G. G. Wijaya, “Analysis of Potential Accidents at Batik using Method of
Hazard Identification and Risk Assessment (HIRA) (Case Study at Griya
Batik Gress Tenan)”, Library of UMS, 2014.
[12] ILO,” Occupational Health and Safety Means for Productivity”, Jakarta:
International Labour Organization, 2013.
[13] Law of the Republic of Indonesia Number 13 of 2003 about Labour.
[14] Puspitasari, “Risk Mapping using Method of HIRARC (Hazard
Identification Risk Assessment and Risk Control) in Workshop Bay 7 at
PT. Alstom Power Esi Surabaya”, Bachelor thesis of S-1 of Institut
Teknologi Sepuluh November, 2011.
[15] P. Hughes and E. Ferrett, “ Introduction to Health and Safety at Work 3rd
ed”, Slovenia: Elsevier, 2007.
[16] T. Pyzdek, “The Six Sigma Handbook, Revised and Expanded: A
Complete Guide for Green Belts, Black Belts, and Managers at All
Levels”, New York: McGraw-Hill, 2003.
[17] W. Susihono and F. A. Rini,“ Management System of Occupational
Health and Safety (K3) and hazard identification (Case Study at PT.
LTX Cilegon-Banten)”, Spektrum Industry, Vol. 11, 2, 117-242, 2013.
200