Risk identification and assessment in a battery-manufacturing industry using FMEA method, and estimating the ratio of the cost of accidents to prevention

 The health and safety of the employees of any industry is one of the most important issues to prevent the occurrence of accidents. This study aimed to identify and assess related risks in a battery-manufacturing industry using FMEA method and estimate the ratio of the cost of accidents to prevention.

 In this descriptive and analytical study, the production activities of the industry were first identified. Then the work process, employee duties, and Potential risks were determined by the HAZID method. Evaluation and prioritization of risks were done using FMEA method. Risks whose RPN was higher than 145 were determined as important risks and the ratio of incident cost to accident prevention was calculated.

In 62 active units of this industry, 716 risks were identified and prioritized, 16 of which (2.23%) had RPN above 145 with the highest priority. The financial pulp unit with falling and fire hazards and the assembly unit with the risk of fumes and lead dust leakage with RPN 245 were among the most dangerous units and hazards identified in the industry. In all units except one unit, the ratio of the cost of accidents to prevention varied from 1.2 to 25.

 The results showed that it is necessary to consider the correction of the important risks by the industry officials, according to the set priorities so that potential accidents caused by these risks are minimized. This prioritization can play an effective role in optimal risk management and reduce related costs.