Optimizing Workplace Safety: A Comprehensive Analysis Of Accident Risks Through FMEA And RCA Methods

Occupational health and safety (OHS) is the key to the company's growth in modern industry. Awareness of OHS has a positive impact on employees financially and non-financially. Indifference to OHS can be fatal, causing harm. OHS includes the establishment of a safe work environment through various approaches. Work accident data at PT. XYZ reaches 36% of the workforce, not yet meeting the government's zero accident policy—workshop at PT. XYZ has 9 types of OHS Risk. This study will use an assessment method using the Failure Mode and Effect Analysis (FMEA) method. After identifying and assessing these risks, improvement proposals will be made using Root Cause Analysis (RCA). Judging from the risks that need to be overcome immediately from the RPN value obtained, namely operating a gas-cutting machine with a value of 71.94, the eye is exposed to iron splashes during the turning process with a value of 64.51. Finally, interference with the eye during the welding process with a value of 60.11 is broken down through the RCA method to find the root cause of the problem. Then, a proposal for improvement is made.


Introduction
PT XYZ is engaged in the manufacturing and distribution of cement.The main task of PT XYZ is to focus on shipping, so many shipping processes use truck transportation, which occasionally experiences damage and requires quick repairs to speed up the shipping process.During the repair process on the truck, there is also a high risk of work accidents that can impact workers' safety and health.In carrying out machine repairs, many workers still ignore PPE and other aspects.OHS, which can have a negative impact if neglected.[1].
Occupational Safety and Health (OHS) helps support the progress of quality and sustainable development in human, economic, social, and environmental aspects and supports important values whose application benefits all aspects of human life.[1].
Work accidents can be caused by physical and mental injuries, as well as poor working conditions and lack of training for workers [2].The company uses external resources, such as vendors, to manage machine repair in the maintenance department of PT XYZ.PPE equipment already owned includes gloves, welding glasses, safety shoes, sandblasting special masks, and protection helmets.However, this company has no specific plan to anticipate and reduce accidents during fabrication.All they do is provide regular safety explanations to workers.
When conducting operational analysis of work accidents using FMEA (Failure Mode and Effect Analysis) and RCA (Root Cause Analysis) methods to help identify potential hazards and find out the root cause of the problem [3].The difference between this article and previous research is the addition of fishbone in the root cause analysis method.In contrast, the discussion and results in this study are more explicit and actual.

Research Methods
This chapter analyzes occupational health and safety risk factors in the maintenance dept of PT XYZ.With the Failure Mode and Effect Analysis (FMEA) technique and the Root Cause Analysis (RCA) method, a risk assessment is carried out in the company workshop area, and observation and interviews with related personnel staff carry out data collection.[2], [3].The results of these observations are used to identify the causes and categorize the hazards for which improvement strategies can be developed.[4].
The data saw a high rate of accidents between January and November 2022, with 36% of the total accidents occurring at several locations, including Cargo Workshop, Workshop, Duta Seven, Barokah Sejahtera Workshop, and Aziz Motor.This study aims to identify factors affecting worker safety in PT XYZ's maintenance department using FMEA and RCA methods.

Failure Mode and Effect Analysis (FMEA)
FMEA is an engineering technique used to determine, identify, and eliminate known failures, problems, errors, and the like from systems, designs, processes, and services before they reach consumers [5].In the context of Occupational Health and Safety (OHS), a failure is a hazard that can arise from a process [6].This is based on an analysis of the potential causes of the disturbance, the probability of occurrence, and how to prevent or handle it [7], [8].The results of this analysis help determine which causes are prioritized.Furthermore, the main causal factors of work accidents are analyzed using the fishbone diagram.Risk analysis is carried out to determine the level of risk, which is a combination of the likelihood of occurrence and the severity of the risk occurring (severity or consequences) [9].

Severity (S)
Severity is set in levels ranging from 1 to 10.A score of 10 indicates the level with the most severe impact, while 1 represents the lowest impact level [10].

Occurance (O)
The occurrence or occurrence of occupational hazards is graded from 1 to 10.A score of 1 indicates an almost impossible event, while a 10 indicates an almost unavoidable event [10].

Detection (D)
detection or detection is determined in levels ranging from level 1 to level 10.Level 10 tools cannot control or detect the occurrence of work accidents, while level 1 work accident detection tools can control the occurrence of work accidents [10].

Root Cause Analysis (RCA)
Root Cause Analysis (RCA) is an in-depth investigation into the cause or causes of an identified problem, complaint, mismatch, unmet requirement, or undesirable condition.The simplest way to analyze the cause of an event is to describe 5 (Why) at least 5 times until finding the root cause of the event [3], [11].

Data Collection
This research uses the Failure Mode and Effect Analysis (FMEA) method to analyze the risk of work accidents using data from PT XYZ This research uses random sampling [12], ordinal scales, and Likert scales to measure variables and interpret social phenomena.Likert scales are used to compare and interpret the  This study surveyed two respondents, an OHS employee and a staff member from a cargo plant, to understand the impact of failure modes on work schedules.Risk assessment data based on Severity, Occurrence, and Detection scales for the PT XYZ study can be taken from the scales and ratios provided by respondents and committees.

Data Processing
The data processing carried out by researchers in this study consists of the following stages: Calculation of RPN (Risk Priority Number) in the workshop of PT.XYZ In Table 9, the RPN calculation shows that the 3 highest RPN values, namely 71.9, 64.5, and 60.1, must be handled immediately so that the risk impact does not exceed or become high.Which will be continued in the discussion of priority analysis [2], [13].

Prioritization Analysis at PT. XYZ Workshop
Ranking of risk factors based on RPN Value at PT. XYZ workshop when sorted from highest value to lowest value [14].Table 7 shows the priority scale for the PT XYZ control process, including risk assessment of gas use, material safety, and not using PPE.The results of the above data will be further processed in the next stage, namely the fishbone diagram, which will be developed further [15].

Fishbone Diagram
To analyze the causes of the many accidents at PT XYZ, we can use a Fishbone diagram, commonly called a cause and effect diagram obtained from the highest RPN value.
The explanation of the fishbone diagram picture of machine repair is as follows: 1. Environmental conditions or workplaces limited by hot air can affect worker safety.2. Methods: Workers are not complying with Standard Operating Procedures (SOPs) and need to undergo retraining to improve their understanding of the importance of complying with SOPs. 3. Materials: Using improper materials can affect the quality of the truck engine.4. Human: Lack of accuracy and discipline of workers using Personal Protective Equipment (PPE) can cause frequent workplace accidents.5. Engine: Maintenance of the engine should be done by doing daily checks to maintain and control the engine, especially on truck engines.

Figure 2 Fishbone repairing lathe machine
The explanation of the welding fishbone diagram image is as follows: 1. Environment: An inappropriate layout can majorly affect the welding process.2. Methods: Workers do not follow SOPs.Training is needed to increase understanding of the importance of complying with SOP. 3. Material: Workers need to pay attention to the storage of welding wire to maintain quality and ensure the welding process runs smoothly.4. Human: Lack of awareness of workers in using Personal Protective Equipment (PPE) when working. 5. Machine: Lack of worker awareness in maintaining welding equipment can result in unstable welding equipment performance.6.
Explanation of the fishbone diagram of gas cutting machine repair, namely: 1. Environment: Proper layout is important to avoid unwanted problems in the gas-cutting process.
2. Methods: Training and adherence to SOPs are required to ensure workers perform tasks according to procedures.3. Materials: Rusty materials can hurt the gas-cutting process, so it is necessary to pay attention to the quality of the material to maintain performance.4. Human: Workers' awareness and thoroughness in using PPE during the gas-cutting process is very important.5. Machine: It is important to ensure the regulator functions properly by maintaining the gas-cutting tool to prevent damage.
After analyzing the fishbone diagram model, the 5 main causes of each accident can be identified [16].The data obtained from the analysis of the fishbone diagram will be developed using the RCA method.

Root Cause Analysis
At this stage, RCA aims to analyze the root causes of the problem to mitigate the risks of the right work accident to prevent the re-occurrence of the same work accident [17], [18].After knowing the results of the analysis of the table above, it is continued by describing each form of work accident by using the question (why) at least 5 times, which can be seen in the discussion diagram below [19], [20].RCA due to eye contact with iron sparks while operating the lathe.The FMEA method analysis obtained the 3 largest RPN values to control and focus on the proposed improvements to the main causes of failure at the 3 largest RPN values [21].Then, we continued with the proposed solution from the RCA method to find out the root cause of the results obtained previously from the FMEA method [22], [23].Then, the stage of using RCA is the 5 why system, which is carried out by repeating the same question starting with the why question at least 5 times until finding the root cause of work accidents [24], [25].

Conclusion
From the research conducted using FMEA and RCA methods, it is known that workers still lack awareness of the use of PPE, with the results of the calculation of RPN as many as 3 events with the highest value.After data processing, suggestions for improvements to the root causes of work accidents in the workshop process are given by providing proposals to minimize and overcome the occurrence of work accidents in the workshop PT.XYZ.

Figure 3 Figure 4
Figure 3 Fishbone welding machine

Figure 5
Figure 5 Rca operating lathe machine

Table 1
Occupational accident data

Table 2
Data failure mode

Risk Assessment Data Based on Severity at PT. XYZ WorkshopTable 3
Risk assessment data based on severity

Risk Assessment Data Based on Occurrence at PT. XYZ WorkshopTable 4
Risk assessment data based on occurrence

Table 7
Priority analysis results

Table 8
Results of RCA analysis

Table 9
Proposed solution from the RCA method