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Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.

1, 2024 | 103 – 112

JSTI
Jurnal Sistem Teknik Industri

Hazard Identification Using Task Risk Assessment


Method and Bowtie Analysis (Case Study: PT. Varia
Usaha Beton)
Hasyim Asyari1 and Dika Setianingsih2
1,2
Department of Industrial Engineering, Faculty of Engineering, Universitas Jenderal Soedirman, Jl
Mayjen Sungkono, Purbalingga, Central Java, 53371, Indonesia

Abstract. PT. Varia Usaha Beton is a subsidiary of PT. Semen Indonesia Beton, which
produces various types of products. PT Varia Usaha Beton (BSP Purwokerto) has an open
work area where there are potential hazards such as physical factors, chemical factors and
ergonomic factors. The aim of this research is to identify hazards, assess risks and control
risks in the production process of ready-mixed concrete so that workplace accidents can be
minimized. The methods used in this research are task risk assessment and bowtie analysis.
Based on the research results, it was found that 1 risk belonged to the low category, 27 risks
belonged to the medium category, and 11 risks belonged to the high category. Based on the
bow-tie method, the major risks are exposure to fly ash and cement dust, risk of diesel spills,
and risk of electric shock. The main causes of workplace accidents are pipe leaks and
improper diesel filling. The main risk effects of workplace accidents are worker injury, and
fire. The bowtie analysis method determines that the risk of electric shock is due to a damaged
cable and the existing protective barrier is intended to replace the damaged cable. This risk
has consequences, namely injuries to workers.

Keyword: Bowtie Analysis, Hazard Identification, Ready-Mixed Concrete, Task Risk


Assessment

Received 22 November 2023 | Revised 25 January 2024 | Accepted 29 January 2024

1. Introduction

Every job has potential dangers. If potential hazards are not addressed and controlled, they can
potentially lead to fatigue, musculoskeletal problems, injuries, and possibly even occupational
accidents [1]. The International Labor Organization (ILO) states that there are 1.1 million deaths
every year due to occupational diseases or accidents [2]. Occupational accidents can be avoided
by knowing and recognizing the various potential hazards in the work environment [3]. Therefore,
it is necessary to control hazards by identifying and then identifying potential hazards in the work
area. Danger is any situation or action that has the potential to cause accidents or injuries to
people, damage to machinery, or other disruptions [4]. Occupational safety and health (K3) are
conditions and factors that affect or may affect the health and safety of workers in the workplace

*Corresponding author at: [Universitas Jenderal Soedirman, Jl Mayjen Sungkono, Purbalingga, Central Java, 53371,
Indonesia]
E-mail address: [[email protected]]
Copyright © 2024. TALENTA Publisher Universitas Sumatera Utara
p-ISSN: 1411-5247 | e-ISSN: 2527-9408 | DOI 10.32734/jsti.v26i1.14417
Journal Homepage: https://talenta.usu.ac.id/jsti
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 104

(OHSAS 18001:2007, 2007). The implementation of occupational safety and health protection
(K3) is very important, especially in companies with direct contact with the construction industry,
so that employees can feel safe, comfortable, healthy and secure [5]. According to Restuputri &
Sari (2015), to reduce or eliminate hazards that may lead to workplace accidents, risk management
activities are required, including hazard identification, potential hazard analysis, risk assessment,
risk control, and monitoring and evaluation [6]. By implementing K3, we can prevent accidents,
damage or illnesses caused by accidents at work and thus save costs that could arise from
accidents [7]. The occupational safety and health management system (SMK3) is part of the
company's overall management system in the context of controlling risks related to work activities
in order to create a safe, efficient and productive workplace [8]. According to the Decree of the
Minister of Manpower and Transmigration RI No. 609 of 2012 on Settlement Guidelines and
Occupational Diseases, industrial accidents are accidents that occur in the context of industrial
relations. An employment relationship can mean that an accident occurs due to work-related
reasons or while carrying out work [9].

PT Varia Usaha Beton (BSP Purwokerto) has an open work area where potential hazards such as
physical factors, namely noise, chemical factors including the form of solids, liquid particles, gas,
mist, aerosol, etc. exist vapor, while the ergonomic factors that occur, namely there is a mismatch
between the worker and the tools or equipment used in the work. Furthermore, workers' lack of
understanding of the recognition of hazards that may occur during work performance may be one
of the main factors responsible for the high number of occupational accidents in construction
projects [10]. Therefore, it is necessary to identify hazards, conduct a risk analysis and control the
potential hazards.

One of the methods used in this research is the Task Risk Assessment (TRA) method. Task Risk
Assessment (TRA) is a hazard identification method carried out to find out what and how great
are the potential hazards encountered during activities in order to prevent occupational accidents
and control these hazards [11]. This method is useful for identifying dangerous risks related to
work or a task. Risk is an impact that can have both positive and negative effects on the project
due to the uncertainty that occurs [12]. With the TRA method, a risk assessment is carried out,
with the help of which the level of risk is determined in terms of the probability of occurrence
(likelihood) and the severity that can be caused [9]. Risk assessment is carried out in order to
properly analyze and evaluate the possible risks and impacts [13]. A risk analysis is then carried
out from the risk assessment, whereby the risk analysis is a systematic process for calculating the
level of the existing risk. The expected result of the risk analysis is a hazard classification. This
highlights hazards that should be considered as priorities for emergency management programs
[14].

Managing the risk of occupational accidents requires real breakthroughs that can not only measure
the risk but also mitigate in detail all causal factors and impacts resulting from an accident risk
[15]. A method capable of solving risks in a structured manner, from assessment to mitigation of
cause and effect factors with multiple controls, is the Bowtie analysis method. Bow-tie analysis
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 105

or BTA is a technique that refers to a butterfly-shaped chart that represents events. the risks one
faces, simply put. However, the bow-tie methodology is an adaptation of three traditional safety
system techniques: fault tree analysis, causal factor diagram, and event tree analysis [16]. This
bowtie analysis graphically represents the relationship between hazards, initial events and
possible consequences, thereby supporting the process of identifying the main causes and
consequences associated with risks, as well as identifying the control steps necessary to avoid or
reduce risks [17]. The advantage of the bowtie analysis method is that it allows researchers to
distinguish between controls that reduce the probability of a spike event occurring and controls
that reduce the magnitude of the consequences, which can reduce the magnitude of the expected
consequences. In addition, bowtie analysis can also be used for all types of risks.

In bowtie analysis, recovery measures are required to reduce potential impacts when exposure
control measures fail and to prevent potential increases in health risks [18]. Restorative actions
are carried out by implementing remedial actions to reduce the impact of the consequences listed
on the right side of the diagram. This research was carried out with the aim of providing
information and assisting HSE officers with PT. Varia Usaha Beton (BSP Purwokerto) in
identifying dangerous risks that may arise and assessing risks in the production process of precast
concrete using the Task Risk Assessment method and knowing the causes and effects of potential
hazards, as well as providing recommendations for improvements and control systems the bow-
tie analysis method to minimize occupational accidents that occur.

2. Research Method

This research was conducted at PT. Varia Usaha Beton (BSP Purwokerto) in the HSE department.
The subject of this study is the dangers that exist in the production process of ready-mixed
concrete. The variables in this research are hazard identification (task phase, failure mode,
consequence analysis, recovery analysis), risk assessment and risk control. Risk detection
techniques include brainstorming, surveys, and distributing questionnaires [19]. The data sources
used in this research are primary data and secondary data. Primary data was collected through
observation and interviews. Observations were carried out directly in the production process in
the area of the mixing plant, during the material filling process and during the production of
concrete samples. Interviews were conducted with several related parties, in particular the head
of the Health Safety and Environment (HSE) team and workers in the mixing plant area.
Interviews were conducted with the HSE team leader to obtain an assessment of the extent and
severity of the potential hazard. Secondary data was obtained from company data, including
company profiles, standard operating procedures (SOP) and HIRARC data in 2022. This research
phase begins with determining the research objectives, namely identifying dangerous risks, risk
assessment and risk control in the ready-mix concrete manufacturing process to prevent industrial
accidents occurring minimize. The steps in preparing a task risk assessment are, first, determining
the type of work to be analyzed, second, identifying materials, equipment or work procedures,
third, analyzing the potential hazards in each work activity, fourth, determining the level of risk
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 106

for each work activity and finally the necessary ones Define protective measures [20]. The
following evaluation criteria are used in this research:

Table 1 Degree of Probability [21]


Levels Description Information
5 Very likely/almost certain Can occur with any disease/is the most common
4 Probably Probably happens often
3 Moderate Can happen multiple times
2 not how The possibility of this happening is rare
1 Rarely Can only occur under exceptional conditions

Table 2 Severity (Severity Level) [21]

Levels Description Information


Deadly, more than one person. Toxic release with widespread impact, very large
5 Catastrophic
financial losses and long-term impact on cessation of all activities
4 Significant Serious injury to several people, major losses and interruption of production
3 Moderate Moderate injury. Requires medical attention
2 Irrelevant Requires first aid/minor injury, moderate financial loss
1 Insignificant There were no injuries and there were minor financial losses

Table 3 Risk Matrix [21]


Consequences (Severity)
Scale
1 2 3 4 5
5 5 10 15 20 25
Probability

4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5

Risk control is based on a hierarchy of controls, namely elimination, substitution, technical,


management and PPE. Then, from the identified risk categories, the dominant risk variable is
extracted from the risk identification and assessment results and then an analysis is carried out
using the bowtie method to identify the causes, effects and controls for each risk that arises.

3. Results and Discussion

3.1. Risk Assessment Task

Task Risk Assessment (TRA) is a hazard identification method carried out to find out what and
how great are the potential hazards encountered during activities in order to prevent occupational
accidents and control these hazards. Based on the risk identification and risk assessment
performed, activity steps are determined to have a low to extreme level of risk. The job variables
are then grouped according to risk level and then risk control is carried out. Risk control is based
on a hierarchy of controls, namely elimination, substitution, technical, management and PPE.
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 107

Table 4 Material Preparation Risk Assessment Task


Ready-mixed concrete
Project/task name : Workspace : warehouse
production
Material
Project/task description :
preparation
Reference Specific Identify potential
S L R Risk control
number task/activity steps hazards
Administration: There are traffic
Accidents in the controllers (cleaning staff/warehouse
3 2 6
factory area staff) when trucks maneuver for
1 Loading materials
loading and unloading.
Slipped due to
2 3 6 PPE: Use of safety shoes and helmet
slippery storage area
Administration: The operator ensures
Exposed to fly ash
3 4 12 that the hose connections are installed
dust
correctly.
Material
2 Air pollution from Administration: Regular inspection
Unloading 2 3 6
clogged hoses and maintenance of hoses.
Exposure to addictive
3 2 6 PPE: Use of gloves and masks.
substances
Fill material into Hit backwards by a Administration: There is a dedicated
3 3 3 9
the cold container wheel loader lane for the use of wheel loaders.
Fire caused by spilled
Refueling the Administration: There is a container
4 diesel fuel while 4 3 12
wheel loader for storing spilled diesel fuel.
refueling

Table 5 Risk Assessment Concrete Production Process


Ready-mixed concrete
Project/task name : Workspace : Batching Plant
production
Concrete production
Project/task description :
process
Reference Specific Identify potential
S L R Risk control
number task/activity steps hazards
Load sand and Falling material falling
1 stones into the while the conveyor belt 2 4 8 PPE: Wear a safety helmet
mixing tub is running
Material impairment due
Administration: Check the
to defective conveyor 3 2 6
conveyor belt regularly.
Conveyor belt belt
2
operation Administration: Do not touch the
Jammed conveyor 3 2 6 conveyor belt when the
conveyor belt is in operation.
Administration: Understanding
Using a dust Air pollution from
3 3 4 12 the application of WI dust
collector clogged dust collectors
collector cleaning.
Fell due to the slippery PPE: Use of safety shoes and
2 3 6
Activities in the stairs in the control room helmet.
4
control room Electric shock due to an Substitution: Replacing a
4 2 8
electrical short circuit damaged cable with a new cable.
Administration: Regular
An oil leak occurred due
5 Use of hoses 3 2 6 maintenance and inspection of
to a broken hose
hoses.
Slipped due to slippery PPE: Use of safety shoes and
2 3 6
production area helmet.
Was hit/knocked by a Administration: When loading
6 Loading truck mixer mixer truck that was 3 2 6 the truck mixer, there is an
about to load helper or a kernet.
Decrease in production
2 4 8 PPE: Use of a helmet.
materials
Breathing problems due
2 4 8 PPE: Use of masks.
Work in the to dusty production areas
7
production area Technology: The vibrator area is
Noise 3 4 12
covered.
Administration: Do not touch the
Finger hit by generator
3 3 9 generator fan while it is
fan
operating.
Use of generator
8 Substitution: Replacing damaged
sets Electrical short circuit 4 3 12
cables with new cables.
The roof of the generator Replacement: Replacement of
2 3 6
house collapsed the generator roof.
Noise 2 3 6 PPE: Use of earmuffs/earplugs
Air compressor Slipped due to oil
9 Administration: There is an oil
operation leakage due to air 3 3 9
storage container
compressor motor leak
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 108

Table 6 Risk Assessment Task Production of Concrete Samples


: ready-mixed
Project/task name concrete Workspace : Quality assurance laboratory
production
:Sample
Project/task description
preparation
Specific
Reference
task/activity Identify potential hazards S L R Risk control
number
steps
Inhaling fly ash and
cement dust while mixing 2 4 8 PPE: Use of masks
concrete
Exposure to addictive PPE: Use of gloves and
1 Concrete mix 3 2 6
substances masks
Administration: Do not
Influenced by the rotation
3 2 6 touch the concrete mixer
of the mixer motor
while it is in operation
Pour concrete Affected by spilled PPE: Use of gloves and
2 1 4 4
into forms concrete mix safety shoes
Drying of When the sample was
PPE: Use of safety shoes
3 concrete lifted, the concrete 2 3 6
and helmet
samples sample was crushed
Administration: Change
There is a puddle of
4 Sample soaking 3 3 9 the soaking water of the
water
sample regularly
Engineering: Installation
Exposed to the explosion
3 2 6 of screens on pressure
Compressive of the test object
5 testing machines
strength test
PPE: Use of gloves and
Hit by test subject 2 3 6
safety shoes
Tools fall when cleaning PPE: Use of gloves and
2 3 6
Pattern cleaning the mold safety shoes
6
of the mold Wedged in the pattern
2 3 6 PPE: Use of gloves
shape

3.2. Bowtie Analysis

After identifying the dominant risk variable from the results of risk identification and assessment,
the bowtie method is then used to identify the causes, effects and controls for each risk that arises.
From the task risk assessment method, the two variables with the highest risk were taken with a
risk value of 12, namely the risk of exposure to fly ash dust and the risk of electric shock.

Threat Preventative Barrier Top Event Mitigative Barrier Top Event

Material
The connecting pipe Clean the pipes regularly to
Unloading
to the cement silo is ensure no clogged material When pouring Use
blocked remains cement and fly ash, Respiratory
appropriate
stay away from pipe diseases
joints PPE

The connection The silo filling Imposing strict Forgetting or not


Make sure the pipe is
between the silo SOP is well Exposed to fly sanctions against using appropriate
connected properly
truck and the silo implemented ash dust violators PPE
before filling the silo
pipe is loose

Wash hands after


Use of gloves disassembling Skin irritation
the materials

Regular
Leakage maintenance and
service of silo pipes

Routine
Leak not detected
inspection

Figure 1 Bowtie Analysis Risk of Exposure to Fly Ash Dust


Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 109

From Figure 1, it is clear that the main event in the material unloading process is the risk of
exposure to fly ash and cement dust. There are three treatments at this top event: The connecting
pipe to the cement silo is blocked with a preventive barrier, namely cleaning the silo pipe
regularly. The second treatment then provides a preventive barrier to the connection between the
truck bulk and loose silo pipes by first ensuring that the connecting pipe is correctly installed
before the material is poured into the cement silo. In addition, the filling of the material into the
cement silo must also be carried out in accordance with the applicable SOP. When dealing with
pipe leaks, there is a preventative barrier, namely regular maintenance and upkeep to prevent
leaks. There is then escalation control on this barrier, namely through routine inspections of the
escalation factors through undetected leaks. Then the presence of this treatment causes a
consequence, namely breathing problems, by mitigating the barrier, namely through distancing
when disconnecting pipe connections and using appropriate PPE such as masks. Then an
escalation factor arises from this barrier, namely intentional or forgotten actions of workers using
PPE with possible escalation control, in particular by imposing strict sanctions on workers who
do not use PPE. The second consequence of skin irritation is the weakening of the barrier, namely
wearing gloves when breaking down the material and washing hands after breaking down the
material.

Threat Preventative Barrier Top Event Mitigative Barrier Top Event

Use of generator
sets Use
Provision of a medical
Replace damaged Use standard team to provide first aid appropriate
There is a
cables with new electrical in the event of an PPE Injured workers
damaged cable cables installations accident

Providing strict
The operator Forgotten or not
SOP for Use sanctions
Touch the cable There are suffered an using appropriate
operation of appropria against
with wet hands K3 signs electric shock PPE
generator sets te PPE violators
Forgetting or
Providing strict
intentionally not
sanctions against
using appropriate
violators Turn off the power
PPE Operations are
source or keep it away Provision of APAR
The operator is Be careful when carried out in (light fire Fire
accordance with from dry, non-conductive
careless or does operating the extinguisher)
the applicable objects
not concentrate on generator set
the work SOP

Figure 2 Bowtie Analysis Risk of Electric Shock

From Figure 2, it is clear that the biggest event when using a generator is the risk of electric shock.
There are 3 treatments at this top event, namely treating damaged cables with a preventive barrier,
namely by replacing damaged cables with new cables and using standard electrical installations.
Then the second treat is touching the cable with wet hands with a preventative barrier, namely the
implementation of SOPs for the use of machines, there are K3 signs for the flow of electricity and
the use of PPE, where in this barrier there are escalation factors for this Operators who forget or
intentionally fail to use PPE can be addressed as part of escalation control by imposing strict
sanctions on workers violating the use of PPE. Then thirdly, if the operator is careless or not
concentrating on performing his work, take a preventive measure: The operator shall exercise
caution when operating the generator motor and operate it in accordance with the applicable SOP.
Consequences arise from this treatment, namely that injured workers receive compensation,
Jurnal Sistem Teknik Industri (JSTI) Vol. 26, No.1, 2024 110

namely through the provision of first aid as first aid in the event of an injury and through the use
of appropriate PPE when there is an escalating factor that leads to failure to mitigate the damage,
viz due to workers' negligence. However, the escalation factor can be overcome through
escalation controls, especially strict sanctions for workers who violate the use of PPE. The
consequences of injured workers are mitigated through the provision of first aid as a first aid
measure in the event of an injury and through the use of appropriate PPE during electrical work
on generator motors when an escalation factor is present that results in failure leads to damage
reduction namely due to the negligence of the workers while using it. While there is adequate
PPE, this escalation factor can be overcome through escalation control, particularly strict
sanctions for workers violating the use of PPE. Then there is a remedy for the consequences of a
fire by turning off the power source and moving the power source away from non-conductive
objects. If an electrical short circuit occurs, use APAR in the event of a fire.

4. Conclusions

This research provides conclusions on hazardous risk identification, risk assessment and risk
control in the precast concrete manufacturing process using the task risk assessment method
combined with the bowtie analysis method to determine the causes, effects and controls that can
be carried out. From work activities where potential hazards have been identified and risk
assessments of the hazards by multiplying the severity value and the probability value. The risk
assessment results are then classified into several risk level categories, namely low, medium, high
and extreme risk levels. It was found that there were up to 1 risk with a low risk category, 27 risks
with a medium risk category and 11 risks with a high-risk category. The risk assessment identified
the high risk of operating the generator set, which poses a risk of electric shock. From the risk
level “High” onwards, a cause analysis and control were carried out using the bowtie analysis
method. The cause of this risk is that a cable is damaged. The control can be carried out by
replacing the damaged cable with a new cable and using electrical installations that comply with
standards. The second cause is touching the damaged cable through controlled use of a generator
motor using appropriate PPE. appropriate and there are K3 signs. The escalation factor is
forgetting or not using appropriate PPE and escalation control imposes strict sanctions on
violators. SOP. This risk results in workers being injured, which can be remedied, in particular
by providing a medical team and using appropriate PPE. The escalation factor is that there are
workers who forget or intentionally fail to use PPE, and escalation control imposes strict sanctions
on workers who violate this. The second effect is the occurrence of fires, which can be contained
by turning off the power source and moving it away from dry, non-conductive objects and using
APAR if a fire occurs.

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