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A Study on risk assessment regarding sausage production line

Biçer, Şeniz
In terms of occupational accidents in the manufacturing sector, the rate of occupational accidents in food manufacturing sector is highest after fabricated metal products manufacturing. Meat processing is the sector with the highest number of occupational accidents among food products. In this study, the risks encountered in meat processing in a sausage production line are evaluated. The reason of selecting the sausage production line is that it contains many of the hazards involved in meat processing . Within the scope of this study, two factories were visited and one of them was chosen to carry out the risk assessment study on the sausage production line. There was already an assessment by the selected facility in which L-type matrix method was applied. In this study, risk assessment is done by Failure Modes and Effects Analysis (FMEA) method and Machine Safety Regulation (MSR) is used as a confirmation tool. The reason why FMEA method was chosen is that it includes detectability component as well as probability and severity which provide a more detailed assessment. Furthermore, the machines which are instensely used for sausage production were examined in the framework of MSR. A checklist called Machine Safety Regulation Checklist (MSRC) was prepared for this examination. Six different sections were determined to carry out the risk assessment study and 121 risks were determined at the end of study. Among these 6 sections, machines were found as the most hazardous section which covers 30% of of the risks, which is the highest percentage that any section has. Moreover, 274 risk factors were determined which are considered as root causes of failures of FMEA method. Again, 30% of the risk factors are machine related. In that respect, machines are evaluated deeply in terms of selected parameters by performing MSRC. Based on the results of the study several preventing actions are recommended, such as moving parts of the machines need to be covered, operation of machines should be prevented while the covers are open and periodic maintenance should be carried out in order to decrease the risk level. One of the drawbacks of machines is the high noise level which can only be reduced by replacing them with new ones. It is highly recommended to supply hearing protectors to the workers until the noise level of machines is reduced below 80dB. Lastly, both production area and work order should be arranged such that non slip floors, adequate ventilation, periodic measurements of environment and personal exposure.