Universidad de
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https://revistas.ug.edu.ec/index.php/iqd
ISSN – p: 1390 –9428 / ISSN – e: 3028-8533 / INQUIDE / Vol. 06 / Nº 02
Facultad de
Ingeniería Química
Ingeniería Química y Desarrollo
Universidad de Guayaquil | Facultad de Ingeniería Química | Telf. +593 4229 2949 | Guayaquil – Ecuador
https://revistas.ug.edu.ec/index.php/iqd
Email: inquide@ug.edu.ec | francisco.duquea@ug.edu.ec
Pag. 31
Risk assessment and control measures for machinery in a food
production company.
Evaluación de riesgos y medidas de control en maquinaria en una empresa de producción de
alimentos.
Jayling Selena Fu-López
1
*; Juan Daniel Calva Valarezo
2
; Hugo Alfredo Pérez Benítez
3
; Franklin Vicente López
Rocafuerte
4
& Jaime Patricio Fierro Aguilar
5
Received: 06/04/2024 – Accepted: 09/06/2024 – Published: 01/07/2024
Research
Articles
X
Review
Articles
Essay
Articles
* Author for correspondence.
Abstract.
The study analyzed the risks in machinery in a food plant using the HRN matrix to design a safety system based on criticality. Information was collected
and each task was analyzed with the HRN matrix to determine criticality. A risk assessment matrix was created, and risks were ranked and prioritized.
Action plans were formulated for critical risks, such as guarding and training requirements. The results showed the criticality of certain equipment, such
as the laminating machine. Ten percent of the tasks involved high risk, highlighting the need for control. It was concluded that the safety system based
on criticality is feasible and would improve safety. A replicable methodology was provided for other plants to analyze risks and implement similar
systems. The proposed system has a high potential impact by reducing accidents and absenteeism. It was recommended to analyze the performance of
the system, perform a cost-benefit analysis, and extend the model to other critical sectors.
Keywords.
Industrial safety; HRN Matrix; Productivity; Criticality; Hazards; Machine guarding; Machine safety.
Resumen.
El estudio analizó los riesgos en maquinaria de una planta alimenticia mediante la matriz HRN, para diseñar un sistema de seguridad basado en criticidad.
Se recopiló información y se analizó cada tarea con la matriz HRN para determinar criticidad. Se creó una matriz de evaluación de riesgos y se clasificaron
y priorizaron. Se formularon planes de acción para riesgos críticos, como requerimientos de guardas y capacitación. Los resultados evidenciaron criticidad
de ciertos equipos como la laminadora. El 10% de las tareas implicaban alto riesgo, resaltando la necesidad de control. Se concluyó que el sistema de
seguridad basado en criticidad es factible y mejoraría la seguridad. Se brindó una metodología replicable para que otras plantas analicen riesgos e
implementen sistemas similares. El sistema propuesto tiene alto impacto potencial al reducir accidentes y ausentismo. Se recomendó analizar desempeño
del sistema, realizar análisis costo-beneficio y extender el modelo a otros sectores críticos.
Palabras clave.
Seguridad industrial; Matriz HRN; Productividad; Criticidad; Riesgos; Protección de máquinas.
1. Introduction
Industrial safety has become a priority to ensure the
integrity of workers and the productivity of manufacturing
companies. The identification and control of risks
associated with machinery operation is a key element in this
matter. This study proposes the design of a specific
machinery safety system for a food production plant,
through the criticality evaluation of equipment [1].
To achieve the objective, it is first proposed to perform a
risk analysis on the machinery using the HRN matrix
methodology to identify critical equipment; then establish
control measures, guard requirements, and training schedule
to mitigate risks; and finally evaluate the technical and
economic feasibility of implementing the proposed safety
system in the food plant [2].
1
Investigador independiente; fujayling@gmail.com ; https://orcid.org/0009-0002-0003-1424, Guayaquil; Ecuador.
2
Investigador independiente; juan_calva1999@hotmail.com ; , Guayaquil; Ecuador.
3
Universidad de Guayaquil; hugo.perezb@ug.edu.ec ; https://orcid.org/0000-0001-7460-4032, Guayaquil; Ecuador.
4
Universidad de Guayaquil; franklin.lopezr@ug.edu.ec ; https://orcid.org/0000-0002-0645-1756, Guayaquil; Ecuador.
5
Universidad de Guayaquil; jaime.fierroa@ug.edu.ec ; https://orcid.org/0000-0003-2725-8290, Guayaquil; Ecuador.
Through the use of methodologies such as the HRN matrix,
a detailed risk analysis is performed and technical,
administrative, and training measures are established to
mitigate critical risks. The proposed system seeks to reduce
accidents and absenteeism, improving safety conditions and
productivity in the company. This article lays the
groundwork for implementing this proactive safety
approach in other plants in the food and beverage sector.
1.1.- Industrial Safety
Industrial safety is a discipline that identifies, evaluates, and
controls occupational hazards to prevent material damage
and accidents. It is important for the integrity and
competitiveness of companies and requires commitment
from all levels of the organization [3].
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Pag. 32
Industrial safety must be comprehensive, prioritized, and
committed to by all. It should be equally considered by all
members of the company, regardless of their function or
hierarchical level [4].
1.2.- Machines and Mechanisms
A machine is a device created by humans to facilitate work
and reduce effort. Machines can be simple, performing
work in a single step, or compound, performing work in
several steps [5]. Simple machines have been known since
antiquity and are used to compensate for a resistive force or
perform weightlifting under more favorable conditions.
Compound machines are formed by a combination of
simple machines [6].
A simple machine is a device that performs work in a single
step. The four most common simple machines are the wheel,
the lever, the inclined plane, and the screw [6]. The wheel
is a circular device that facilitates the movement of heavy
objects. The lever is a rigid bar that rests on a point and is
used to multiply force. The inclined plane is a flat surface
with a slope, used to lift heavy objects. The screw is an
inclined plane wrapped around a cylinder, used to move
heavy objects in a vertical direction [6].
Compound machines are combinations of simple machines.
Compound machines are used to perform more complex
tasks that cannot be performed by a single simple machine
[6].
1.3.- Machinery Safety
Machine safety is a fundamental principle that seeks to
ensure the health of workers. To this end, machines must
meet certain minimum safety requirements from their
design. It is necessary to take precautions during the use,
installation, repair, and maintenance of machines [7].
Machinery safety is important to prevent serious injuries or
even death. Machines can cause a variety of injuries,
including crushing, impacts, cuts, burns, and electrocutions
[8].
To prevent accidents, workers must evaluate the risks
associated with the use of machines and implement safety
measures to mitigate these risks. These measures may
include: Installing machines safely; Selecting appropriate
machines for the task; Installing all safety guards;
Developing a safe work system for the use and maintenance
of the machine [9]. Workers must take safety measures to
prevent accidents with machines. These measures include:
Installing machines safely, Selecting appropriate machines
for the task, Installing all safety guards, Developing a safe
work system for the use and maintenance of machines.
Workers should receive constant training on machine safety
and follow safety instructions.
Safety measures for workers include: Wearing required
clothing and PPE, Checking proper machine maintenance,
Using the machine correctly [10].
Therefore, workers should not: Generate distractions for
operators using machines, Wear loose clothing, rings,
chains, pendants, or even loose long hair; Remove machine
guards; Use an application or machine that has danger signs
or labels [11].
Production machines can be dangerous, so it's important to
take measures to ensure worker safety. These measures
include:
• Risk assessment: Before using any machine, a risk
assessment should be carried out to identify potential
associated hazards.
• Proper maintenance: Machines must be kept in good
working condition through a regular maintenance
program.
• Training and education: All workers who operate
machines must receive adequate training on their safe
use.
• Guards and safety devices: It is essential to have
appropriate guards and safety devices on machines.
• Supervision and monitoring: Constant supervision of
workers operating machines is essential to ensure they
follow established safety measures [12].
1.4.- Worker Safety and Health
Worker safety and health is an important issue in Ecuador.
Each year, thousands of workers are injured or fall ill at
work, which has a significant impact on workers,
companies, and society as a whole [13].
In 2021, there were more than 30,000 workplace accidents
in Ecuador, causing more than 1,000 deaths and more than
20,000 lost workdays. The annual cost of occupational
injuries and illnesses in Ecuador exceeds 1 billion dollars.
The Government of Ecuador has taken measures to improve
worker safety and health, including enacting laws and
regulations, creating supervisory bodies, and promoting
worker and employer participation [14]. However, much
remains to be done to reduce occupational injuries and
illnesses. To this end, it is important that workers and
employers work together to promote a culture of prevention
and awareness at all levels [15].
1.5.- Occupational Risks
Occupational risks are conditions or situations present in the
work environment that have the potential to cause harm,
injuries, or illnesses to workers. These risks can be
classified into four main categories: physical, chemical,
biological, and ergonomic [16].
Hazard Identification and Assessment The first step in
ensuring worker safety and health is to identify existing
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Pag. 33
hazards in the workplace. A variety of methods can be used
to identify hazards, such as workplace inspections, review
of safety records, worker interviews, and risk analysis tools
[17].
Risk Control
Once hazards are identified, control measures must be
implemented to mitigate them. These measures may
include:
• Engineering measures: These measures focus on
eliminating or reducing the hazard at the source. For
example, a barrier can be installed to prevent workers
from coming into contact with a physical hazard, or a
ventilation system can be used to control exposure to
chemical substances.
• Administrative measures: These measures focus on
changing work procedures or work organization. For
example, a safe work procedure can be established for
performing a specific task, or training can be provided
to workers on how to work safely.
• Personal Protective Equipment (PPE): PPE are items
used to protect workers from hazards. PPE should be
used whenever it is not possible to eliminate or reduce
the hazard through engineering or administrative
measures [18].
Risk Mitigation Strategies
Occupational hazards can be mitigated through a variety of
strategies, which can be classified into three main
categories:
• Engineering controls: These controls involve
modifying the workplace or equipment to reduce or
eliminate hazards.
• Administrative controls: These controls involve
changing the way work is done to reduce the risk of
injuries and illnesses.
• Personal Protective Equipment (PPE): PPE is used to
protect workers from hazards that cannot be eliminated
or reduced through technical or administrative controls
[19].
Safety Training
Safety training is fundamental for workers to be able to
identify and avoid hazards, and to correctly use PPE.
Training should be provided to all workers, regardless of
their position or responsibilities [20].
1.6.- Machinery Safety Systems in Factories Industrial
machinery can be dangerous for workers if not properly
maintained or handled. Therefore, it is essential to
implement safety systems on machines to prevent accidents
and injuries [21].
The most common safety systems in industrial machinery
are:
• Guards: Physical barriers that prevent workers from
accessing dangerous areas of the machine.
• Interlocks: Devices that ensure the machine cannot start
if the corresponding guard has not been put in place
[22].
• Emergency stop buttons: Buttons that allow the
machine to be quickly stopped in emergency situations.
• Warning signs: Signs that alert workers to potential
hazards associated with the machinery.
• Personal Protective Equipment (PPE): Equipment that
protects workers from hazards inherent to machinery
and work processes [23].
The proper implementation and maintenance of these safety
systems is essential to ensure a safe work environment in
factories and protect the health and well-being of workers
[24].
1.7.- Risk Assessment
Risk assessment is a process to identify, analyze, and
evaluate hazards in the workplace, determine the likelihood
of adverse events, and assess possible consequences. Its aim
is to implement preventive measures to control and reduce
risks, ensuring a safe environment [25]. Its main advantages
are accident prevention, improved safety culture, reduced
legal liabilities, and increased efficiency.
The stages of the assessment are: hazard identification
through inspections, risk evaluation considering probability
and consequences, determination of controls and safety
measures, application of controls, and periodic monitoring
and review [26].
There are qualitative assessments, which classify risks as
high, medium, or low, and quantitative assessments, which
assign numerical values. Useful tools include hazard
checklists, risk assessment matrices, and specialized
software programs [27].
1.8.- HRN Matrix
The HRN (Hazard Rating Number) method is the main tool
used to quantify and qualify the level of risk in machinery.
Also known as the Risk Rating Number, this method allows
for classifying a risk to determine whether it is acceptable
or not [28].
The effectiveness of the HRN method lies in obtaining a
function that relates the severity of damage to the
probability of occurrence for a given number of exposed
workers, based on an identified risk related to a considered
hazard.
Thus, the HRN method enables a quantitative assessment of
the risk level. This allows for prioritizing risks and focusing
control efforts on those that are most critical. For this
reason, the HRN method is widely used as a valuable tool
in machinery risk management [29].
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Pag. 34
Quantifying Hazard Levels in Machines with the HRN
Method
To quantify the hazard levels in a machine using the HRN
method, all present risks and hazards must first be identified
(e.g., lack of electrical grounding, finger crushing risk,
inadvertent actuation risk, etc.).
Next, the following formula is applied for each identified
hazard:
HRN = LO x FE x DPH x NP
Where:
• HRN = Quantified Risk Level
• LO = Likelihood of Occurrence
• FE = Frequency of Exposure to Risk
• DPH = Severity of Potential Harm
• NP = Number of People Exposed to Risk
The parameters and variables represented in each element
of the formula are listed and quantified in the following
tables.
For the likelihood of occurrence (LO) of an accident, levels
ranging from 0.033 to 15 are used, according to the table
below:
Table 1.- Likelihood of Occurrence (LO)
0.033
Almost impossible
May occur in extreme
circumstances
1
Highly unlikely
But possible
1.5
Unlikely
Although conceivable
2
Possible
But not usual
5
Some possibility
Could occur
8
Probable
Not surprising
10
Very probable
Expected
15
Certain
Without a doubt
For the exposure frequency
Table 2.- Frequency of Exposure (FE)
0.5
Annually
1
Monthly
1.5
Weekly
2.5
Daily
4
Hourly
5
Constant
For the degree of possible injury (DPH):
Table 3.- Severity of Potential Harm (DPH)
0.1
Scratch / Abrasion
0.5
Laceration / Cut / Mild Illness
1
Minor Bone Fracture - Fingers / Toes
2
Serious Bone Fracture - Hand / Arm / Leg
4
Loss of 1 or 2 Fingers / Toes
8
Amputation of Leg / Hand, Partial Loss of Hearing / Vision
10
Amputation of 2 Legs or Hands, Partial Loss of Hearing /
Vision in Both Ears / Eyes
12
Permanent or Critical Illness
15
Fatality
The number of people is given by:
Table 4.- Number of People Exposed to Risk (NP)
1
1 – 2 people
2
3 – 7 people
4
8 – 15 people
8
16 – 50 people
12
More than 50 people
The table below shows the risk levels that can be obtained
through the application of the HRN formula.
Table 1.- HRN (Hazard Rating Number)
Resultado
Riesgo
Evaluación.
0 – 1
Aceptable
Consider possible actions. Maintain
protective measures.
1 – 5
Muy bajo
5 – 10
Bajo
Ensure current protective measures
are effective. Improve with
complementary actions.
10 – 50
Significativo
50 – 100
Alto
Actions must be taken to reduce or
eliminate the risk. Ensure the
implementation of protections or
safety devices.
100 – 500
Muy alto
500 – 1000
Extremo
Immediate action to reduce or
eliminate the risk.
Mayor que 1000
Inaceptable
Stop activity until the risk is
eliminated or reduced.
The color grading ranges from green for acceptable HRN
results to red for levels that are unacceptable and require
immediate intervention. It is important to note that this color
variation was defined by the author of this study. These
colors were chosen because they resemble traffic lights,
making the severities found in the assessment much clearer.
Timeframes to Adapt Machinery to Occupational Safety
Standards
The previous chart should be used to prioritize action. It is
advisable to define the timeframe for taking action to reduce
each result range. Therefore, the following is proposed:
• For the range from 0 to 5, seek improvement
without a defined deadline.
• For the range from 5 to 50, act on risk reduction
within the next 4 months.
• For the range from 50 to 1000, act within a
maximum of one week.
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Pag. 35
• For the range greater than 1000, activities should
be immediately stopped.
Following the presented guidelines ensures better control
over machinery-related occupational accidents, thus
preventing harm to workers' lives and financial losses to
companies.
Safe Modes of Operation and Maintenance
Safe modes of operation and maintenance are essential for
the safety of workers and equipment, helping to prevent
accidents and damage. Common modes include
lockout/tagout to prevent activation during maintenance,
isolation to prevent the release of hazardous materials,
personal protective equipment such as goggles and gloves,
and safe work practices [30].
General principles to ensure safety include planning to
identify hazards, communicating risks and safe practices,
training workers, inspecting equipment, and documenting
activities. Adhering to these measures helps protect workers
and equipment. It is also crucial to use proper tools, follow
manufacturer instructions, maintain order and cleanliness,
be aware of hazards, take breaks, and report unsafe
situations [31].
Zero Access Principle
The zero access principle is a safety approach aimed at
preventing any physical contact between people and
dangerous machine parts [32]. Various protection methods,
such as physical barriers, interlocks, and proximity sensors,
are used to achieve this. The goal of zero access is to create
a "fail-safe" system where it is physically impossible for
anyone to contact a dangerous machine part, even if they
make a mistake.
Modes of Intervention
Modes of intervention range from working completely
outside machine protections to interventions requiring the
dismantling of components or the presence of hazardous
energies. Each mode involves specific challenges and
considerations in terms of occupational safety [33].
Mode 0: Zero Access, Working Outside Protections
- Prevents accidental or deliberate physical access to
dangerous, energized parts.
- Requires tools, keys, or passwords to disable or remove
protections.
- Ensures personnel safety and protection against ejected or
falling objects.
Mode 1 and 2: Interventions Through or Within
Protections
- Require safety systems based on initial risk assessment.
- Before intervening, stop equipment using normal stop
controls, not lockout or emergency stops.
- In Mode 1, the body prevents the closing of guards and
equipment restart.
- In Mode 2, one of the safety control systems must be
locked.
Mode 3: Interventions Requiring Dismantling (Perform
LOTO)
- All sources of hazardous energy must be locked out and
tagged out (LOTO).
- Release any stored hazardous energy.
- All personnel must follow the LOTO procedure.
- Each employee places their own lock and tag; use group
locks if necessary.
Mode 4: Interventions Requiring Hazardous Energy.
- Identify activities involving hazardous energy and attempt
to mitigate them.
- Only allowed if no safer alternative is available.
- Authorized and trained personnel must follow a safe
procedure.
- Restrict access to the work area.
- Minimize the number of people and duration of the
intervention.
- Use "hold-to-operate" controls from a safe distance.
2. Materials and Methods.
Methodology
The methodology employed in this study consisted of the
following stages:
1. Literature Review. -
Initially, a review of secondary sources was conducted to
gather relevant information serving as the theoretical
framework and state-of-the-art on the study topic.
2. Data Collection. -
Detailed information about the production machinery in the
food factory was gathered through:
• Company records
• Direct observation of machines in operation
• Pre-stored data in internal systems
3. Risk Analysis. -
Each activity performed on the machines was analyzed
using the Hazard Risk Number (HRN) matrix to identify
hazards, assess risks, select protection methods, and
determine machinery criticality. The steps involved:
• Identification of potential hazards
• Evaluation of probability and severity of each risk
• Selection of appropriate protection methods
• Creation of the HRN matrix with all information
• Definition of machinery criticality based on risk level
4. New Evaluation Matrix. -
A new matrix was developed to identify hazards,
probability, and severity for each piece of machinery.
5. Risk Classification and Prioritization. -
Risks were classified and prioritized based on the
previously determined probability and severity.
6. Action Plans. -
Specific, feasible, and measurable action plans were
formulated to mitigate identified critical risks.
7. Training. -
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Pag. 36
A training program was conducted for personnel on the
study topics to reinforce their knowledge in safety.
Materials.
➢ For Literature Review:
• Academic databases such as Scopus, Web of
Science, etc.
• Books, scientific articles, and other secondary
sources on industrial safety and risk analysis.
➢ For Data Collection:
• Physical and digital records of the company about
the machines.
• Observation and measurement equipment for on-site
analysis (cameras, lux meters, sound meters, etc.).
• Company specialized software with pre-stored data.
➢ For Risk Analysis:
• HRN methodology and its formats.
• Risk analysis software.
• Digital matrix for documenting results.
➢ For New Evaluation Matrix:
• Probability and severity risk matrix format.
• Software for quantitative risk analysis.
➢ For Risk Prioritization:
• Risk criticality matrix.
• Risk acceptability criteria.
➢ For Action Plans:
• Plan formulation methodologies (5W2H).
• Project management software (MS Project).
➢ For Training:
• Audiovisual material on industrial safety.
• Computer and audiovisual equipment for sessions.
• Manuals and guides for participants.
3. Results.
Analysis of Results
Currently, the company operates 3 traditional cookie
production lines. Line "6" has been considered as the pilot
line due to its modernization, consisting of 7 main
equipment units that facilitate the production process.
Figure 1 illustrates a layout of the cookie area.
Fig. 1 Layout of the Area
A: Biscuit Packaging
B: Biscuit Ovens
C: Biscuit Lamination
D: Biscuit Mixers
For the development of action plans and necessary control
methods, a multidisciplinary team with predefined roles has
been assembled:
• SHE Coordinator: Responsible for analyzing the
methodology.
• Mechanical Technician: Reviews the feasibility of
implementing engineering controls.
• Electrical Technician: Reviews the feasibility of
implementing engineering controls.
• Line Manager: Reviews and approves the collected
information.
• Operator: As the process owner, their participation is
crucial to validate any proposal.
• Thesis Authors: Information gathering and proposal
development.
Based on the developed information, an information matrix
has been created detailing the activity, hazards, area risks,
and risk analysis using the zero access matrix and HRN
matrix.
Task Monitoring
A format has been developed to record activities in the
cookie manufacturing process considering the area,
equipment, task performed, description, frequency,
intervention mode, controls, and action plans. Through
information gathering with operators, the frequency,
number of exposed individuals, and procedures for each
workstation have been documented. Additionally, the
possibility of mitigating existing risks is evaluated, totaling
208 identified tasks.
Table 6 - Number of Tasks Recorded per Equipment
N.
Equipment
Tasks
1
Dough Mixer
15
2
Laminator
55
3
Oven
20
4
Oil Bath
25
5
Conveyors
18
6
Cavannas
57
7
Sealer
17
Total
207
According to Table 6, the total number of tasks recorded for
each equipment in the food factory is shown. Some
observations:
• The laminator and the cavannas have the highest
number of recorded tasks (55 and 57 respectively). This
indicates that they are complex equipment with
numerous processes and intervention points.
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• The oven, oil bath, and dough mixer also have a
relatively high number of tasks (20-25), suggesting
they are critical equipment in the process.
• The conveyors and sealer have the fewest number of
tasks (17-18), indicating they are simpler equipment or
have fewer critical intervention points.
• In total, 207 tasks are recorded across the 7 equipment
types. This gives an idea of the scope of the production
system.
• Analyzing the number of tasks per equipment type is
useful for gaining an initial understanding of the
criticality and complexity of each machine. This
information should be supplemented with other data for
designing the safety system.
Modes of Intervention
Identifying tasks in each equipment allows categorization
based on the level of exposure to exposed parts to determine
the likelihood that operators may suffer accidents during
their daily tasks. Table #7 shows the number of tasks
performed under different modes of intervention.
Table 7 - Intervention Modes by Equipment
Equipment
Tasks
Mode
0
Mode
1
Mode
2
Mode
3
Mode
4
Dough
Mixer
15
2
4
3
3
3
Laminator
55
6
8
5
13
23
Oven
20
1
0
0
15
4
Oil Bath
25
14
0
0
5
6
Conveyors
18
0
0
0
9
9
Cavannas
57
12
17
0
27
1
Sealer
17
16
0
0
0
1
According to Table 7, the different intervention modes per
equipment in a food factory are shown. Some observations
include:
• The Laminator has the highest number of tasks (55) and
the most interventions in the most critical modes (Mode
4 with 23 and Mode 3 with 13). This indicates that the
Laminator is a highly important and critical equipment
for the process.
• The Oven has few interventions in the most critical
modes (Mode 4 with 15 and none in Mode 3). However,
it has 20 tasks, which still indicates its relevance.
• Conveyors and the Sealer have the lowest number of
tasks (17-18) and few or no interventions in critical
modes. They are important but not as critical
equipment.
• Criticality analysis considering total tasks and
intervention modes is key to prioritizing equipment in
the security system design. According to this table, the
Laminator and Cavannas appear to be the most critical.
Risk Assessment
To assess risks, a matrix was developed categorizing
hazard, intervention mode, exposure frequency, access ease,
likelihood of occurrence, and severity of injury. An analysis
was also conducted with activity type, description, hazard,
risk, initial risk level according to HRN (probability,
exposure, severity, persons exposed), controls to be applied,
and the timeline for resolution to establish a work schedule.
The first activity in the matrix involves lifting the kneading
trough, associated with mechanical risks due to mechanical
handling of loads. This activity is performed several times
per shift, depending on production demand, thus the
exposure frequency is high (4). The operator can easily
access this area (3), making it "highly likely" for an injury
to occur, with potential for a "recordable" injury requiring
medical treatment (2). This results in a "high risk" score.
In the HRN Evaluation Matrix, the probability of strikes
occurring when lifting the kneading trough is possible but
uncommon (2), as it is a routine activity, operators are
constantly exposed (5), the severity of injury could lead to
loss of limb (4), and two people are exposed. As a result,
there is a score of 80, indicating a high risk that should be
addressed within a week.
Table 8 - Identified Risk Levels
Equipment
High
Risk
Medium
Risk
Low Risk
Total
Mixer
1
0
14
15
Laminator
9
12
34
55
Oven
3
1
16
20
Oil Bath
4
0
21
25
Conveyors
3
5
10
18
Cavannas
-
1
56
57
Sealer
-
0
17
17
Total
20
19
168
207
% Risk
10%
9%
81%
100%
Según la Tabla 8, se muestran los niveles de riesgo
identificados en las tareas de cada equipo:
• 81% of the registered tasks have low risk, 9%
medium risk, and 10% high risk. This indicates
that the majority of tasks are low-risk.
• The laminator has the highest number of high-risk
tasks (9), followed by the oil bath (4). These appear
to be the most critical equipment in terms of safety.
• The oven also has a significant number of high-risk
tasks (3). It's another important equipment to
consider.
• Cavannas and the sealer have no detected high-risk
tasks. They are apparently the least critical
equipment.
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Pag. 38
• Overall, the laminator, oven, and oil bath should
be prioritized in the safety system design due to
their higher risk levels.
• Task-level risk analysis is crucial to identify
critical points to manage on each machine.
Guard Requirements
After analyzing the risks, it was determined that guards need
to be installed to prevent access to exposed parts. For this,
it's necessary to engage a contractor specializing in
designing, testing, and installing these guards.
Operators perform daily tasks near the equipment, exposing
them to risks of entrapment and burns. Therefore, it is
considered necessary to install fixed guards on equipment
like the laminator that can only be removed by technicians
for maintenance purposes.
Training Schedule
For the development of this section, the specifications of
Second Supplement No. 309 were taken into consideration.
[34]
The schedule outlines the topics to be covered and the
proposed dates for training personnel to reinforce
knowledge in machinery safety, as well as to disseminate
changes in safety protocols.
Staff planning is done in advance, with three rotating shifts
each week. The schedule is organized so that all shifts can
receive the same training, lasting a maximum of 40 minutes
without interrupting their activities. Table #10 details the
topic, responsible person, and week in which the training
will commence upon project approval.
Table 9.- Training Schedule
Topic
Facilita
tor
Week
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
Hazard
Identificatio
n
Assista
nt 1
X
X
X
Intervention
Modes
Assista
nt 2
X
X
X
Machinery
Safety
Assista
nt 3
X
X
X
SHE Maps
Update
Assista
nt 4
X
X
X
According to Table 9, the machinery safety training
schedule spans 12 weeks and includes the following topics:
• Risk Identification (3 weeks): Conducted by Assistant
1 in weeks 1, 2, and 3.
• Modes of Intervention (3 weeks): Led by Assistant 2 in
weeks 4, 5, and 6.
• Machinery Safety (3 weeks): Facilitated by Assistant 3
in weeks 7, 8, and 9.
• SHE Maps Update (3 weeks): Assistant 4 in weeks 10,
11, and 12.
• The schedule reflects a progressive training approach,
starting with basic risk concepts and progressing to
more specific aspects of machinery safety. The final
update aims to reinforce procedures established in the
new system.
• The 12-week duration allows for thorough
reinforcement of concepts and ensures adoption by the
workers. The schedule appears appropriate and aligned
with the identified training needs from the previous
analysis.
4. Conclusions.
This study enabled a detailed analysis of machinery-related
risks in a food production plant using recognized
methodologies such as the HRN matrix. Findings
highlighted the criticality of certain equipment, notably the
laminator, which showed the highest number of high-risk
tasks.
Risk-level evaluation demonstrated that while the majority
of registered tasks were low-risk, a significant percentage
(10%) posed high risks to worker safety. This underscores
the need for implementing control measures for critical
tasks.
The study concludes that a machinery safety system based
on risk assessment is feasible and can substantially enhance
worker conditions. Proposals such as guard requirements
and the training schedule support this proactive approach to
prevention.
The research provides a replicable methodology for other
industrial plants to analyze risks and implement machinery
safety systems. The formats and tools presented facilitate
the adoption of this proactive approach to industrial safety.
The proposed machinery safety system based on criticality
has the potential to significantly reduce accidents,
absenteeism, and associated costs. The study lays the
groundwork for improving industrial safety in the
manufacturing sector globally.
Future research directions should include evaluating the
performance of the implemented system, conducting cost-
benefit analyses of adopted measures, and expanding the
model to other sectors with critical machinery in food
production lines.
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Guayaquil
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Ingeniería Química y Desarrollo
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ISSN – p: 1390 –9428 / ISSN – e: 3028-8533 / INQUIDE / Vol. 06 / Nº 02
Facultad de
Ingeniería Química
Ingeniería Química y Desarrollo
Universidad de Guayaquil | Facultad de Ingeniería Química | Telf. +593 4229 2949 | Guayaquil – Ecuador
https://revistas.ug.edu.ec/index.php/iqd
Email: inquide@ug.edu.ec | francisco.duquea@ug.edu.ec
Pag. 39
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Facultad de
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https://revistas.ug.edu.ec/index.php/iqd
Email: inquide@ug.edu.ec | francisco.duquea@ug.edu.ec
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