Hazard Identification and Risk Assessment (HIRA)

In every manufacturing process which is sequences of activities to produce

tangible products, manufacturers need natural resources and human resources.
During the manufacturing process that always involves human resources, natural
resources, and list of equipment, there are list of potential hazard that can occur.
Hazard is any existing or potential condition that can lead to injury, illness, or
death to people; damage to or loss of a system, equipment, or property; or damage
to the environment. Since loss of economics value and fatalities of human are one
of hazard effect, manufacturers has to know list of potential hazard and method to
overcome occur hazards. An effort to overcome this issues start with hazard
identification and risk assessment.
The purpose of hazard identification and analysis is to identify and
develop a list of hazards for each job in the organization that are reasonably likely
to cause people to be exposed to injury, illness or disease if not effectively
controlled. The hazard identification phase involves reviewing equipment,
machinery, work areas, work practices, processes, procedures, and hazardous
substances to carefully evaluate all sources of hazards for plant employees.
In determining HIRA, there are several steps that must be done. The stages are as
follows:

Sorting activities to be carried out into sub smaller events and specific

Identify potential hazards for each sub-activity

Determination of possible risks (dangers and effects the possibilities)

Determining how to prevent and control the hazards

Conclusion of potential hazards and risks involved for each activity

Conclusion to overall job

We must understand the terminology of hazard and risk first in order to

assess further about HIRA. Hazard is an event or physical condition that has the
potential to cause fatalities, injuries, property damage, infrastructure damage,
agricultural loss, damage to the environment, interruption of business, or other
types of harm or loss. Meanwhile, risk is the potential losses associated with a
hazard, defined in terms of expected probability and frequency, exposure, and
consequences.

Activities

Loading Sugarcane
to milling process

Potential Hazard

the operator was

hurt by slipped
sugarcane

Be squeezed
Milling Process

Clean the Tank

Hazard Effect
Death,
permanent
disability
Minor injuries
Medium
Injuries, the
body can still
work
Minor injuries
Medium
Injuries, the
body can still
work
Death,
permanent
disability

Level of
Hazard
Effect

Level of
Possibility

Risk

material spilled

Minor injuries

Minor injuries
Medium
Injuries, the
body can still
work

Fall down and

slips, especially
at the high tank

Prevention and
Control

Final
Risk
M

Using PPE and obey

production SOP

Using PPE and obey

production SOP

M
Periodic check on
pipeline

L
L

Using PPE and obey

production SOP

Charging material
in pretreatment
process

Screw conveyor
maintenance

material spilled

Be squeezed

Environmental
pollution,
wasted

Minor injuries

Medium
Injuries, the
body can still
work
Death,
permanent
disability

Fall

Death,
permanent
disability

Welding

eyes damage
face damage
Burden

H
H
M

M
M
M

Process Equipment
installations

Evaporation units
maintenance

Death, injurries,
and
dysfunction of
the body

equipment
dimension

Slipped, fall
down

Periodic check on
pipeline

L
M

Using PPE and obey

production SOP

Good practice of
standard operating
procedure.
Skilled workers.

H
H
M

Using PPE and obey

production SOP

M
M
L

Good practice of
standard operating
procedure.
Skilled workers.

material indirect
contact

Fermentation units
maintenance

Distillation Unit
Operates

Heat Exchanger
maintenance

Irritation

Using PPE and obey

production SOP

Equipment
dimension

Slipped, fall
down

Good practice of
standard operating
procedure.
Skilled workers.

material indirect
contact

Irritation

Using PPE and obey

production SOP

Equipment
dimension

Slipped, fall
down

Good practice of
standard operating
procedure.
Skilled workers.

material indirect
contact

Irritation

Using PPE and obey

production SOP

Using PPE and obey

production SOP

Using PPE and obey

production SOP

Skin contact direct

Pipes and
direct contact with
equipments leakege skin

Medium
Injuries, the
body can still
work
Medium
Injuries, the
body can still
work

Failure of
temperature
control inside
storage tanks;
raw materials being
exposed
to high temperature

Electrical
installation

Fire, permanent
injuries

Check control system

regularly.

Stung by
electricity

Injuries NonPermanent

Usage of protective
equipment.
Good practice of
standard operating
procedure.
Provision of fire
safety equipment

Falls for high

installation
location

Death, injurries,
and
dysfunction of
the body

Using PPE and obey

production SOP

Circuit breakers
fitted to all
generators,
appliances and
cables, conducted
regular inspections
and maintenance of
the equipment,
Provide fire safety

Short Circuit

Fire,
equipment
failure