Hazard Identification and Risk Assessment (HIRA) in Textile Industry

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072
Hazard identification and Risk assessment (HIRA) in Textile Industry

Ashokkumar T C1, Dr Muthukumar K2, Manojkumar R M3
1PG student, Industrial Safety Engineering, Bannari Amman Institute of Technology, TamilNadu, India
2Professor, Industrial Safety Engineering, Bannari Amman Institute of Technology, TamilNadu, India
3Senior Safety Officer, Jay Jay Textile Mills Private Limited, TamilNadu, India
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Abstract – This manuscript contains the details on the the risk would reach 25 concerning the chart -Prepared by
hazards and risk level present in one of south India's leading the textile industry as shown in figure.1.
textile industry. This study also briefs about the need, method
and result of the HIRA technique. The HIRA technique is
adopted in the old rotary printing department and dyeing
department to assess the risk levels in terms of quantified
values. The control measures were also developed for each area
and activities identified with potential safety issues. It is found
that the identified hazards majorly categorized under Physical,
chemical, ergonomics, material handling, health and electrical
hazards. The risk level is quantified for all the hazards in the
printing and dyeing department by multiplying the values of
severity and probability.
Key Words: Rotary printer, Loop ager, A-Frame, HIRA,

ALARP
Figure.1. Risk Quantification Chart.
1. INTRODUCTION
Padmini D.S et al.,2010 in their study stated that the hazards
The Textile industries are considered as the heart of the evolved in the Textile industries are grouped under the
manufacturing sectors as they top the list in their numbers. Machine/ mechanical hazard, Electrical hazard, Health
There are about 1381 mills in Tamilnadu with an average Hazards, hazards in material handling Ergonomic hazards,
number of employees accounting about 27. The textiles and another similar kind of hazards. Thillainatarajan.,2019 in
industry can be further divided into five different functional their study explained the occupational health hazards in the
units as listed below, textile sectors such as Byssinosis, bronchitis, diffused lung
disease, and other breathing issues which are mainly caused
 Ginning unit from the improper machine Condition, Ergonomic issues,
 Garment unit ambient issues such as humidity, lighting and ventilation.
 Spinning unit
 Dyeing unit Nazia Malik et al.,2010 examined the workers in the textile
 Weaving unit industries and found that the workers are mostly uneducated
and that is the important factor which makes them fail in
Faisal Hannan 2015 and Nimkar 2016, drafted the HIRA chart understanding the importance of safety in the workplace, it is
specifically for the Textile industry and also stated that HIRA also equally important that the management should commit
is one of the tools in safety engineering used to identify the containing various potential safety issues.
hazards in the workplace. The usual HIRA sheet would entail
the following: The activity for which hira is to be conducted, Hafiz Danish Ashraf et al.,2009 has proposed that the noise
Nature of the work (Routine / Non- Routine), type and level in the industrial premises should only be within the
description of the hazard present, the Consequence or impact noise range as described in the regulation. It is the
due to the hazard, Details of the persons under risk, The management obligation to take necessary actions to contain
existing control measures for each particular hazard, The the exceeding noise level. Tiwari meenaxi et al.,2012 reported
existing risk level for the existing control measures, The that the musculoskeletal disorders are caused by unusual and
additional control measures for each particular hazard, The extreme body postures adopted in the workplace by the
risk level with additional control measures, By whom the workers.
action is to be taken.
2. METHODOLOGY:
The JJG Standard: Hazard identification and risk assessment,
2018., defined the Risk level as a combined element of the There are certain procedures about how HIRA can be
Severity and likelihood of the hazard. The maximum level of undertaken. The HIRA technique can be implemented by
© 2020, IRJET | Impact Factor value: 7.34 | ISO 9001:2008 Certified Journal | Page 2149
performing four different sequential procedures such as likelihood and the Monitor and review- developing the
hazard identification- Consideration of the Potential harmful additional Control measures.
elements, risk assessment- rate the risk as values ranging
from 1 -25, risk analysis- the analysis of the severity and its
3. HAZARD IDENTIFICATION AND RISK ANALYSIS IN PRINTING AND DYEING UNIT.
Risk Level Additional Residual

Machine/ Existing Control
Sl No Hazards Control
Location measures
Measures
P S R P S R
MACHINE HAZARDS
Trench cover
Need to provide
Rotary printing getting rusted
No existing new trench cover
1 machine no.1 and damaged. At 4 3 12 1 3 3
control measures which should not
trench cover any time it can
rust easily.
break
Trench cover
Need to provide
Walking path getting rusted
No existing new trench cover
2 (near colour and damaged. At 4 3 12 1 3 3
control measures which should be
room) any time it can
rust easily.
break
Machine cover is
in the open
condition. Need to close the
Rotating parts door once
Rotary printing No existing
3 are inside. 3 4 12 maintenance 1 4 4
machine no.2 control measures
Operators may work has been
get caught completed.
between rotating
parts
Steam line Insulation Need to provide
Rotary printing
4 insulation provided but got 3 4 12 full cover 1 4 4
machine no.1
damaged damaged insulation.
Duct exhaust Insulation Need to provide
Loop ager machine
5 pump insulation provided but got 3 4 12 full cover 1 4 4
no.1
damaged damaged insulation.
Cables are kept
Loop ager machine Need to remove
6 backside corner Nil 3 3 9 1 3 3
no.1 cables
of loop ager 1
Safety guard not
The mechanical
fixed in floor.
Rotary printing Guard is there, team should fix
7 A-frame may 3 3 9 1 3 3
no.2 but not fixed. the guard on the
damage the
floor.
motor
Safety material
cage not Department in
Safety material
properly charge needs to
provided but not
8 Old Color room maintaining. At 3 4 12 take strict action 1 4 4
maintained
the emergency and keep material
properly
situation, it safely.
cannot be used.
Oil leakage and Need to arrest oil
Loop ager machine No existing
9 insulation also 3 4 12 leakage and 1 4 4
no.1 control measures
not provided. provide insulation
Steam coming
Loop ager machine out from steam Insulation Need to arrest
10 3 4 12 1 4 4
number one line while heat provided steam leakage
setting
Operators walk
and stand on the
machine while Need to change
checking print. If the work practice.
Rotary Printing No existing
11 he slips, 3 4 12 Check the print 1 4 4
machines control measures
hand/leg may after fabric
crush inside coming out.
between the
gaps.
Fabric roll kept Need to remove
Loop ager machine on thermic oil Insulation fabric rolls and
12 3 5 15 1 5 5
no.1 lines and steam provided kept in separate
lines racks
ELECTRICAL HAZARDS
Electrical cable
Close the trench
Electrical cable trench is in an Cover provided,
and wiring should
13 trench near open condition. but the open 3 5 15 1 5 5
properly be
machine no.1 Water getting condition
insulated
stagnated inside.
Arrest leakage
Water from the motor.
continuously Earthing cable The motor should
RP machine no.1 coming out from was provided but be covered fully
14 3 4 12 1 4 4
feeding pump the motor. It may not properly and earthing
contact with live grounded. cable should be
electrical parts. properly
grounded.
Tiles were
broken, sharp
Screen washing No existing Need to change all
15 edges may cut 4 4 16 1 4 4
area tiles control measures broken tiles.
the employees
leg.
OTHERS
Tiles were
broken, it may
cut the
Already informed Need to take strict
16 Colour room employees leg 4 4 16 1 4 4
to management action
and water
getting
stagnation
Pipeline gets
Already informed
17 Colour room damaged and 3 3 9 -- 1 3 3
to management
water leakage
Side Cover is in
hanging Already informed Need to take strict
18 Colour room 3 3 9 1 3 3
condition. It may to management action
fall at any time.
Need to remove
Empty chemical
cans and provide
Empty can storage cans stored
19 Nil 3 5 15 rubber mat and 1 5 5
room under electrical
guard around the
panel
panel
Old sewing
Need to remove
Loop ager machine kept
20 Nil 3 3 9 and utilize 1 3 3
backside near the
properly
backside
Sample fabric
rolls kept very Need to remove
close to the fabric rolls and
Loop ager
21 electrical panel. Nil 3 5 15 provide rubber 1 5 5
electrical panel
If short circuit it mat and guard
is lead to fire around the panel
hazard.
Empty can storage Need to cover
22 Open wires Nil 2 5 10 1 5 5
room wires.
Periodic cleaning
must be carried
out and the
supervisor must
Rotary printing Dust ensure
23 and loop ager accumulation on Cleaning 3 4 12 cleanliness 1 4 4
machines duct duct regularly. Photos
should be sent to
the safety
department with
date and time.
MATERIAL HANDLING
Training must be
Due to overload, provided for
employees workers on
No existing
24 A-frame getting strain 3 3 9 ergonomic 1 1 1
control measures
while moving A- practices that are
frame. to be followed in
material handling.
A-frame should
not load more
Advised printing than 1000 kgs.
Due to overload, department to do The mechanical
25 A-frame 4 5 20 1 5 5
A-frame may tilt. not load more team should
than 1000kgs periodically check
the A-frame
condition.
Safety shoe Strict compliance
provided for to be adopted for
Chances of
protection ( Many the benefit of
workers foot
operators were workers.
getting hit by A-
26 A-frame noticed not 3 2 6 (Incentive for the 3 1 3
frame during
wearing safety day will be cut if
transport of
shoe) and safe the operator is
fabric roll.
handling training found to be
is given. without PPE)
HEALTH HAZARD
Employees Safety shoe, Strict compliance
working with gumboot and to be adopted for
Rotary printing bare feet and gloves are the benefit of
27 and colour making bare hands. provided for 4 3 12 workers. 2 1 2
room Chemical protection ( Many (Incentive for the
infection may operators were day will be cut if
happen. noticed not the operator is
wearing the found to be

mask) without PPE)
Strict compliance
Inhalation of
to be adopted for
chemical fumes
Mask is provided the benefit of
during the
Rotary printing for protection ( workers(
machine's
28 and colour making Many operators 4 3 12 Incentive for the 2 1 2
normal
room were noticed not day will be cut if
operation and
wearing a mask) the operator is
while colour
found to be
mixing
without PPE)
ERGONOMIC HAZARD
Training must be
Strain caused provided for
due to improper workers on
No existing
29 All employees loading and ergonomic
control measures 2 3 6 1 2 2
unloading practices that is to
operation. be followed in
material handling.
Table.1. HIRA Chart – Old rotary printing process
Risk Level Additional Residual

Existing Control
Sl No Hazards Consequences Control
measures
Measures
P S R P S R
MANUAL CHEMICAL HANDLING, LOADING & STORAGE
While mixing the
dyes and Should be
chemical there is Eye injury, PPE's are given. regularly trained
1 a chance of Chemical burn, Chemical safety 3 3 9 on the safe 2 3 6
chemicals will etc., training is given handling of
splash on the chemicals
eye.
while carrying
chemical from Should be
PPE's are given.
store to the Eye injury, regularly trained
Chemical
2 machine there is Chemical burn, 3 3 9 on the safe 2 3 6
handling safety
a chance of etc., handling of
training is given
chemicals will chemicals
spill.
Stickily adopted
While mixing the
to use PPE.
dyes and PPE's are given.
Should be
chemical there is Respiratory Chemical
3 3 3 9 regularly trained 2 3 6
a chance of problem handling safety
on the safe
inhalation of dye training is given
handling of
particles
chemicals
Chemical
There is a chance Should educate
handling safety
of a violent the workers
Scalding training is given.
4 reaction if some 2 4 8 about the 1 4 4
accidents Reactive
of the chemicals reactivity of
chemicals kept
get reactive chemicals
separately
OTHERS
Sharp should
The operator
Contact with grind properly
must take
5 sharp edges in Cut injury 3 2 6 and damaged 1 2 2
precautions
the trolly handle should be
during movement
removed
Training must be
Strain caused provided for
due to improper workers on
No existing
6 loading and Back strain 2 3 6 ergonomic 2 1 2
control measures
unloading practices that are
operation. to be followed in
material handling.
DYEING MACHINE
Chances of
getting burn
injury if touch Operators should
the machine with 1. Nitrle and PVC be regularly
7 bare hand while Burn Injury gloves are 3 3 9 trained and create 2 3 6
loading and provided. awareness about
unloading the hazards.
fabric into the
machine.
Chances of Strict compliance
hitting the should be
passengers or Leg or hand Safety shoes are adopted.
8 3 2 6 2 2 4
workers while injury provided Operators should
moving the be regularly
trolley. trained.
Stagnation water
should be cleaned
regularly. Strict
workers foot compliance
may get affected should be
Safety shoes are
9 due to chemicals Foot injury 4 3 12 adopted. 2 3 6
provided
and water spilt Operators should
on the floor. be regularly
trained and create
awareness about
hazards.
All steam line
Chances of
Awareness should be
getting burn
training is insulated and
10 injury if contact Burn Injury 2 3 6 1 3 3
providing barricade the area
with the steam
regularly. if it able to touch
line
easily by workers
The slippery
surface should be
Chances of
cleaned
operator slip and
Can lead to head The operator immediately.
fall from the
11 injury/ Body must take 3 2 6 Operators should 2 2 4
stand during
injury precautions. be regularly
operating the
trained and create
machine.
awareness about
hazards.
Chances of
The operator
slippage from water should be
12 Leg injury must take 3 2 5 1 3 3
wet and water cleaned regularly.
precautions
stagnation in
ground
Periodic cleaning
Chemical spillage must be carried
slippage causing No existing
13 in the machine 3 2 6 out./ Any spillage 3 1 3
injury control measures
area. must be reported
immediately
Table.2. HIRA -Dyeing unit
RESULT AND DISCUSSION REFERENCES
Risk analysis for different activities was undertaken in the 1. Textile Business-JJG, “Hazard identification and risk
dyeing unit and old rotary printing unit. It is found that the assessment Standard”, March 2018.
risk level was ranging from 5 to 12 for the dyeing process 2. D.S Padmini..,” Unsafe work environment in
and 6 to 20 for the printing process and also the risk level is garments industries”, journal of environmental
qualitatively assessed into low, medium, high, very high research and development, volume 7 no.1A 2012.
through contour colorings. As a result of this study, various 3. Thillainatarajan, “Review on Occupational Health
hazards were identified and the practical control measures Diseases in the textile industries”, International
were developed. Research Journal of Engineering and Technology,
Volume: 06 Issue: 10, Oct 2019
CONCLUSION 4. Nazia Malik..,” Role of hazard control measure in
occupational health and safety in the textile industry
This study has delivered various hazards under mechanical, of Pakistan, Pak j.agri sci vol 47(1), 72-76,2010.
electrical, material handling, chemical, ergonomic, and the 5. Hafiz Danish asraf.,” frequency of hearing loss among
temperature extreme aspects and also control measures textile workers of wearing units in Karachi, Pakistan.
following the hierarchy of elimination substitution 6. Tiwari meenaxi..,” Causes of Musco- skeletal
engineering administration and PPE. It has been observed disorders in the textile industry”, Issn 2329-3563.vol
that several processes carried out in the dyeing and printing 1(4),4850,December 2012.
unit has a very high level of risk which requires immediate 7. Vasim khatik..,” The pioneering study on
control measures. This study also reveals that the risk rating identification of fire hazards in cotton ginning
of a medium level is associated with several activities for industries of nandurbar region of Maharashtra”,
which control measures have been recommended. volume-2, Issn 2277-8179.
8. Nimkar 2016,‘Chemical Safety at the Workplace in
Textile Industry’ NimkarTek Technical Services Pvt
Ltd.
9. Faisal Hannan 2015, Risk Assessment and Evaluation
of Basic Health and Safety Facilities (A Report of
Textile Industry Gujrat, Pakistan) (2014) Safety View
Magazine.

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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 07 Issue: 03 | Mar 2020 www.irjet.net p-ISSN: 2395-0072

Hazard identification and Risk assessment (HIRA) in Textile Industry

Key Words: Rotary printer, Loop ager, A-Frame, HIRA,

3. HAZARD IDENTIFICATION AND RISK ANALYSIS IN PRINTING AND DYEING UNIT.

Risk Level Additional Residual

wearing the found to be

Table.1. HIRA Chart – Old rotary printing process

Risk Level Additional Residual

Table.2. HIRA -Dyeing unit

RESULT AND DISCUSSION REFERENCES

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