Issuu

Risk Management in Industry 4.0 Maintenance: Identifying and Addressing Hazards

C Ravi Kumar1 , Manish Kumar Mishra2 , R. K Mishra3

1M.Tech Scholar, Bhilai Institute of Technology, Raipur, Chhattisgarh, India

2Assistant Professor, Dept. of Mechanical Engineering, Bhilai Institute of Technology, Raipur, Chhattisgarh, India

3Associate Professor, Dept. of Civil Engineering, Bhilai Institute of Technology, Raipur, Chhattisgarh, India ***

Abstract - This research investigates hazards and risks specific to maintenance activities in Industry 4.0. It includes firsthand observations from an industry visit, identifying potential hazards using the Hazard Identification and Risk Assessment(HIRA)methodology.Theresearchemphasizesthe importance of a comprehensive safety approach for Industry 4.0, providing practical control measures and recommendationstomitigatemaintenance-relatedrisks.The outcomes highlight the transformative potential of Industry 4.0andoffervaluableguidancetostakeholders,policymakers, and practitioners. Implementing the research's recommendationsenablesorganizationstonavigateIndustry 4.0 confidently, fostering a safe and efficient future.

Key Words: Industry4.0,HIRA,Maintenance

1.INTRODUCTION

TheconstructionindustryinIndiaisexperiencingrapid growth, driven by urbanization and infrastructure development.Itisprojectedtoreachamarketvalueof$1.4 trillionby2025.Thedemandforresidentialconstructionis also increasing, with a need for 25 million mid-range and affordable housing units by 2030. India has allocated a substantialbudgetforinfrastructuredevelopmentunderthe National Infrastructure Pipeline, focusing on renewable energy,roads,highways,urbaninfrastructure,andrailways. Initiatives like the Smart City Mission and the PMAY-U program are promoting modernized urban planning and constructiontechnologies.

However,thisgrowthcomesatacost,astheconstruction industryhasaconcerningsafetyrecord.Accidentsresultin hundreds of fatalities among workers each year, with the construction sector accounting for a significant portion of these deaths. The AEC industry, which encompasses architecture,engineering,andconstruction,playsabroader roleindesigning,planning,managing,andmaintainingbuilt environments. It involves various professionals, including architects, engineers, construction managers, and tradespeople,whocollaboratetocreatefunctional,safe,and aestheticallypleasingstructures.Qualitycontrol,safety,and effectiveprojectmanagementareessentialaspectsofboth theconstructionandAECindustries.

The construction industry in India is booming due to urbanizationandinfrastructureprojects,butworkersafety

remainsasignificantconcern.TheAECindustryplaysamore comprehensive role in creating and managing built environments, emphasizing design, planning, and efficient projectexecution.

Industry 4.0, also known as the fourth industrial revolution,involvestheintegrationofadvancedtechnologies, such as the Internet of Things (IoT), big data, and cloud computing, into various sectors, including manufacturing. Construction 4.0 aligns with Industry 4.0 and implements similar technologies within the construction industry to enhanceefficiencyandinnovation.TheIndustrialRevolution has evolved through several stages: 1.0 relied on human effort and steam-powered machines, 2.0 introduced electricityandmoreefficientmachines,and3.0sawtherise ofautomationandelectronicsinproduction.Industry4.0,the fourth revolution, focuses on Cyber-Physical Systems and leveragescutting-edgetechnologiestoenablereal-timedata analysis and intelligent decision-making in manufacturing processes. The goal of Industry 4.0 is to integrate these technologiesacrossallindustrialsectors,leadingtoenhanced business performance and improved quality of life for workers.Byembracinginnovativetechniques,companiescan achieveflexibility,efficiency,andintelligencewhilereducing humaneffortandrisksassociatedwithtasks.

Safety is a critical consideration in both manufacturing and construction industries. The introduction of new technologiesinIndustry3.0increasedtheneedforsafetyand securitymeasures,whichremainrelevantinIndustry4.0.In the construction industry, safety considerations must permeate all phases of operations, and adherence to protocols and regulations is crucial to mitigate risks and protect workers and the public. The evolution of industrialization has led to improved workplace environments and better engagement between employers and employees in addressing health and safety issues. Advanced tools, risk management standards, and safer devicescontribute to monitoringandcontrolling the work environmenteffectively.Whilechallengespersist,Industry 4.0 offers the potential for further advancements in safety andefficiencyacrossvariousindustries.

The research highlights how Industry 4.0 is revolutionizing maintenance practices for businesses. It highlightsthefollowingkeypoints:

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072

• Predictive Maintenance (PdM): Industry 4.0 enables organizations to implement predictive maintenance, which allows them toforesee equipment failures and takeproactivepreventiveactions.Smartsensorsplaya crucial role in detecting anomalies and notifying techniciansfortimelyintervention.

• Proving the Value of Maintenance: Data analytics and comprehensive metrics enable organizations to showcasethetangibleimpactofmaintenancepractices on their bottom line. Shifting from a reactive to a proactive mindset rewards effective maintenance strategiesandcontinuousimprovement.

• Building a Solid Foundation: Organizations need to establishawell-builtpreventivemaintenanceprogram withessentialsteps,providingaroadmapforsuccessful integrationwithIndustry4.0andminimizingchallenges duringthetransition.

• FocusonDataCollection:Good-qualitydataiscrucialfor leveragingIndustry4.0effectively.Detailed,consistent, anddigitalassetdata,includingmaintenanceactivities, naming conventions, and key performance indicators (KPIs),shouldbeprioritized.

• Creating a Reliability Culture: A successful implementation of Industry 4.0 relies on fostering a reliabilityculturethatembraceschangeandcontinuous improvement. This involves establishing guiding principles,formalprocesses,opencommunication,and recognizingadaptabilityandinnovation.

• Starting Small with Predictive Maintenance: Organizations can begin with condition-based maintenance (CBM) as a stepping stone towards fullfledged predictive maintenance. Startingsmall allows learning,buildingexpertise,andgainingconfidencein thepowerofpredictivemaintenance

Research gap identified in the literature review is investigatingtheroleandimpactofIndustry4.0technologies on maintenance processes in industrial facilities, with a specificfocusontheeffectivenessandsustainabilityofdigital technologiesinenhancingmaintenancepractices.

2. FACILITY MANAGEMENT

Toestablishthegroundworkfortheresearchbystating theproblem,theauthorcollecteddataandobservationsfrom the Facilities management (FM) of a MNC. located in Bengaluru, Karnataka. This activity offered firsthand experience of actual working conditions and a practical understandingofatheoreticalconceptrelatedtothefieldof integrated facility management. Several noteworthy advantages of adopting such quantitative data collection approachinclude:

• •Anopportunitytoconnectwithleaders,professionals, entrepreneurs,policymakers,andcorporateindividuals who generously share their knowledge, insights, and experiences.

• •Towitnessandengagewithactualfacilitymanagement sites, machinery, systems, and interact with highly skilledandexperiencedstaff.

• •Togaininsightsintothecompany'spoliciesconcerning production,qualitycontrol,andservicemanagement.

• •Tounlocknumerouspossibilitiesforcorporatetraining enhancingone'semployabilityprospects.

• •Tocomprehendthecollaborativeeffortsofmanagers, engineers, employees and other staff in achieving commonobjectives,presentingvaluablemanagement lessons.

• •To recognize the importance of safety in facility managementandmakeinformeddecisionsaboutfuture work areas such as facility maintenance, equipment handling,signaling,andsafetyprotocols.

Duringtheindustryvisit,anindustryembracingIndustry 4.0 technologies, I had the opportunity to witness a wide range of activities and advanced equipment in action. The visit provided valuable insights into the company's commitment to technological excellence and overall maintenanceandmanagementoftheirfacilities.Company's impressive array of equipment included Vacuum Circuit BreakerPanels,DieselGenerators(1,2,and3),Lifts(Pl3,Pl4, and Pl5), and Uninterruptible Power Supply Panels. These state-of-the-art technologies exemplify their dedication to adopting Industry 4.0 principles, ensuring efficient and reliablepowersupplyanddistribution.Theimplementation ofSlidingDoors,SequencingBatchReactors(SBR)Unit,Flow Switches, Solar Fencing Zones, and Solar Power Fencing ZonesdemonstratedHoneywell'sfocusonsustainabilityand energy efficiency, utilizing renewable energy sources to reduceenvironmentalimpact.Moreover,Itwasobservedthat meticulousattentiontofacilitymaintenanceandcleanliness, evident through activities such as Reception Cobweb Cleaning,CarpetShampooingMachineService,WaterPond Deep Cleaning, and Floor Deep-Cleaning & Shampooing. These initiatives indicate Honeywell's dedication to maintainingasafeandpleasantworkingenvironmentforits employees.Thecompanyalsoshowcasedtheircommitment toemployeewell-beingwiththeprovisionofGrr&LrrRest Rooms, ensuring comfort and relaxation during breaks. Additionally,Inoticedaseamlessintegrationoftechnology andcivilworkwithinthefacility,alongwithwell-designed Signage Boards and Signage Markings, indicating efficient wayfinding and facility management. Furthermore, the companyemphasizedpestcontrolactivities,illustratingtheir attention to maintaining hygiene and cleanliness in their operationalspaces.Overall,thevisittotheindustryprovided a comprehensive understanding of their progressive approach to Industry 4.0, sustainable practices, and their unwavering commitment to maintaining a technologically advanced, safe, and environmentally conscious working environment.Theexperiencereaffirmedtheimportanceof adoptingcutting-edgetechnologiesandbestpracticestostay aheadintoday'scompetitiveindustriallandscape.

International

(IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072

Research Journal of Engineering and Technology

3. METHODOLOGY

The research employs a specific methodology aimedat implementing task-specific control measures to effectively reduce or eliminate hazards identified during metro construction projects. The methodology utilizes the data collectionanditsanalysisfollowedbyHazardIdentification and Risk Assessment with Controls (HIRAC) method to thoroughly analyze potential hazards across various maintenanceactivities.

Hazard Identification, Risk Assessment, and Control (HIRAC)isamethodicalandproactiveprocessemployedto ensure the safety and well-being of individuals within a workplace by effectively managing potential occupational andhealthhazards.TheprimaryaimofHIRACistoidentify potential risks, evaluate their severity and likelihood, and implementappropriatemeasurestominimizeoreliminate these risks. The initial step in HIRAC involves identifying hazards, where a thorough analysis of the workplace is conducted to recognize any conditions, activities, or substances that may pose harm to employees or other stakeholders.Hazardsencompassabroadspectrum,ranging from physical dangers to chemical, ergonomic, and psychological factors. Following hazard identification, the RiskAssessmentstageensues.Duringthisstep,theseverity and likelihood of each identified hazard are assessed to determinethelevelofriskitpresents.Risksarecategorized ashigh,medium,orlow,allowingorganizationstoprioritize andaddressthemostcriticalissuesfirst.

Subsequently, the Control Implementation phase is initiated, wherein measures are devised and applied to mitigate or eliminate the identified hazards. These control measures may take the form of engineering modifications, administrativeprotocols,ortheimplementationofpersonal protective equipment (PPE) requirements. Continuous monitoringandevaluationareintegralthroughouttheHIRAC processtoensuretheeffectivenessofimplementedcontrols. Regular reviews of the workplace and its processes are essential to identify emerging hazards, reassess risks, and make necessary adjustments to control measures. CompliancewithHIRACprinciplesisnotonlyessentialfor employee safety but is also a legal obligation in many jurisdictions.Byadheringtosafetyandhealthlegislationand employing HIRAC, organizations demonstrate their commitment to employee well-being, reduce workplace accidents and injuries, enhance productivity, and avoid potentiallegalliabilities.

3.1HazardIdentification

Hazardidentificationistheprocessofdetectingpotential risks and dangers within a workplace or work practice. Understanding the nature of hazards is crucial for a comprehensivehazardidentificationprocess.Thesehazards can be categorized into various types, including physical, biological, chemical, and psychosocial, all of which are commonly found in workplaces. Performing a thorough hazard identification requires significant effort and can be time-consuming.Consequently,periodichazardidentification maybenecessarytoensureitseffectiveness.Oneeffective

approach is to divide the workplace into distinct zones, enablingtheidentificationandprioritizationofhigh-priority areas based on hazardous elements like equipment, substances, processes, or environmental conditions. To achieveaccuratehazardidentification,itisessentialtogather insights and opinions from domain experts who possess ampleknowledgeandarefamiliarwiththeworkprocedures, suchasworkersandsupervisors.

Risk assessment involves estimating the level of risk associatedwithidentifiedhazardsanddeterminingwhether thelevelofriskisacceptableforthegivenworkcontext.This assessmentisconductedbasedonevaluatingthe"likelihood" and"consequence"ofpotentialhazardouseventsoccurring. For tasks with high-risk potential, appropriate measures must be implemented to reduce the risk to an acceptable level, ensuringa safe working environment.The identified hazards are listed and ranked based on their level of consequences and likelihood. Consequences refer to the severityofthepotentialimpactorharmcausedbytherisk, whilelikelihooddenotestheprobabilityoftheriskoccurring. Mathematically,theriskleveliscalculatedbymultiplyingthe likelihood(L)andseverity(S).

RiskLevel=LxS

Table -1: Ratingscaleforassessingtheprobabilityofan eventtakingplace

Table -2: Ratingscaleforassessingtheseverityofan eventtakingplace

3.2RiskAssessment

Level Descriptor Example detailed description 1 Rare May occur only in exceptional circumstances 2 Unlikely Limited potential of occuring 3 Possible Potential to occur some time 4 Likely Will probably occur in most circumstances 5 Almost Certain Is expected to occur in many circumstances

Level Descriptor Example detailed description 1 Insignificant Hazard Identified, Near Hit with no injury 2 Minor First Aid Treatment, 1-2 days lost time injury 3 Moderate Medical treatment, >3 days lost time injury 4 Major Extensive injuries such as permanent disability/ amputations and/or resuscitation 5 Catastrophic Single / Multiple Fatalities Table -3: RiskMatrix Likelihood Severity 1 (A) 2 (B) 3 (C) 4 (D) 5 (E) Rare Unlikely Possible Likely Almost Certain 5 Catastrophic 5 10 15 20 25 4 Major 4 8 12 16 20 3 Moderate 3 6 9 12 15 2 Minor 2 4 6 8 10 1 Insignificant 1 2 3 4 5

Theriskmatrixisavaluabletoolusedforevaluatingand prioritizing potential risks in various contexts, such as projects or organizations. It involves assessing each risk basedonitslikelihoodandseverity,andthenplottingthemin the appropriate cells on the matrix. This visual representation helps identify high-priority risks with significant consequences and enables the allocation of resourcesaccordingly.Tofurtherenhanceitsusability,risks areoftencategorizedintodifferentlevels,distinguishedby distinctcolors,makingiteasierfordecision-makerstograsp theimportanceofeachriskandtakeappropriateactionsto managethemeffectively.

"The severity of risk, as indicated by the risk relative score,directlyinfluencesthelevelofnecessaryintervention. Ahighriskrelativescoredemandsimmediateanddecisive actiontomitigatepotentialhazards.Whenconfrontedwith anintermediateriskscore,adequatepreparationisessential to effectively manage and control the associated risks. Conversely,situationsmarkedbyalowriskrelativescoreare considered acceptable and tolerable, requiring less urgent attention."

Table -3: Descriptionofactionscorrespondingtodifferent risklevels

Priority for Control Implementation

Allhazardsandrisksmustbecontrolled,risklevelprovidesa ‘priorityforaction’.

Severe

Moderate

Unacceptable level of risk – Cease activity immediately. Otheractionandcontrolmeasures mustbeimplementedandtheextremerisk reducedtoALARPbeforeworkcancommence. Re-assess risk after any new control is implemented.

Otheractionandcontrolmeasuresshouldbe consideredtoreducetherisktoALARP. Ensure allexistingmeasuresaremonitoredforadequacy. Re-assess risk after any new control is implemented.

• Elimination:Themosteffectiveapproachistoentirely removethehazardfromtheworkplace.Thismayentail substitutinghazardousmaterialswithsaferalternatives orredesigningprocessestoeliminatepotentialdangers altogether.

• Substitution: If complete elimination is not feasible, substitutioninvolvesreplacinghazardousmaterialsor practiceswithlessriskyalternatives.

• Engineering Controls: As previously mentioned, engineering controls involve modifying the work environment or equipment to minimize the risk of exposuretohazards.

• AdministrativeControls:Whenengineeringcontrolsare inadequate,administrativecontrolsareimplementedto limitexposureandenhancesafeworkpractices.

• PersonalProtectiveEquipment(PPEs):PPEsserveasa final line of defense, protecting individuals from remaining risksafterall other control measureshave beenputinplace.

4. RESULT

TheHazardIdentification,RiskAssessment,andControl methodisathoroughandextensiveapproachusedtoensure safetyandhealthinaworksite.Hence,thisresearchfocuses onapplyingtheHazardIdentification,RiskAssessment,and Controlmethodtotheobservedmaintenanceactivities.

Theassessmentresultsfortheseactivitiesareshownin Figure1,whereatotalof134hazardswereidentifiedacross different sub-tasks. The identified potential hazards for all theobservedactivitiesarelistedinTableBelow.TheHazard Identification,RiskAssessment,andControl(HIRAC)method wereappliedtothesesub-tasksfollowingthemethodology discussedearlier

Low

Otheractionandcontrolmeasuresmaynotbe necessarybutconsidermakingallriskALARP. Monitorallexistingcontrolsforadequacy. Re-assess risk after any new control is implemented.

Whendeterminingappropriatehazard/riskcontrolmeasures applytheALARPprinciple:ReducethelevelofrisktoAsLow AsReasonablyPracticable.

3.3RiskManagement

Inthisresearch,riskcontrolmeasureswereestablished by carefully assessing the identified hazards and implementing a combination of engineering controls, administrativecontrols,andpersonalprotectiveequipment (PPEs).Itisessentialtoadheretoawell-definedhierarchyof risk control measures for effective risk management, ensuringthesafetyandwell-beingofindividualsinvolvedin theprocess.

The hierarchy of risk control measures is of utmost importance in ensuring the adoption of the most efficient strategies to manage hazards. This hierarchy outlines a preferredsequenceforaddressingrisks:

Fig -1 Distributionofdeterminedinheritriskscores

Figure1representsthedistributionofhazardsbasedon their corresponding risk scores. Each hazard is assigned a risk score based on its potential severity andlikelihoodof occurrence.Therisk scoresaregroupedintothreeranges, andthetableshowsthenumberofhazardsfallingintoeach range.

S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 1 VacuumCircuit BreakerPanel Maintenance Electrical Hazard ElectricShock duetoexposed liveparts InjuryorFatality 5 3 15 1.EngineeringControls:Proper insulationandguarding. 2.AdministrativeControls: Lockout-Tagoutprocedures. 3.PPE:Insulatedgloves,safety glasses. 2 2 4 2 VacuumCircuit BreakerPanel Maintenance FireHazard Electrical overheating Fireleadingto propertydamage orinjury 4 3 12 1.Regularthermalscanningand maintenance. 2.Fire-resistantbarriers. 3.Fireextinguishers. 3 2 6 3 VacuumCircuit BreakerPanel Maintenance Chemical Hazard Exposureto hazardous insulatingfluids Chemicalburns orrespiratory problems 3 2 6 1.UseofproperPersonal ProtectiveEquipment(PPE). 2.Properhandlingandstorage offluids. 3.Emergencyresponse procedures. 2 1 2 4 VacuumCircuit BreakerPanel Maintenance Mechanical Hazard Pinchpointsor movingparts Crushinjuriesor amputations 4 4 16 1.Machineguarding. 2.Lockout-Tagoutprocedures. 3.Propertraining. 2 2 4 5 VacuumCircuit BreakerPanel Maintenance FallHazard Workingat heights Fallleadingto injuriesor fatalities 4 3 12 1.Fallprotectionequipment (harnesses,lanyards). 2.Properscaffoldingand platforms. 3.Propertraining. 3 2 6 6 Diesel Generator Maintenance Mechanical Movingengine parts Worker'shand caughtin machinery 3 2 6 EngineeringControls 2 1 2 7 Diesel Generator Maintenance Electrical Electricshock Electrician exposedtolive wire 4 3 12 Lockout/TagoutProcedures 2 1 2 8 Diesel Generator Maintenance Fire Fuelleak Fireduetofuel ignition 4 2 8 RegularInspection& Maintenance 1 1 1 9 Diesel Generator Maintenance Noise Highnoise levels Hearinglossto maintenance crew 2 4 8 PPE-EarProtection 1 2 2 10 Diesel Generator Maintenance Chemical Dieselfumes Inhalationof toxicfumes 3 3 9 AdequateVentilation 1 1 1 11 Elevatorlift activity Mechanical Elevator entrapment Peopletrapped insidethe elevator,panic, suffocation 4 3 12 Regularmaintenanceand inspectionofliftcomponents 2 1 2 12 Elevatorlift activity Mechanical Elevatordoor malfunction Peoplecaught betweenclosing doors 3 2 6 Doorsensorsandsafety mechanismsinstallation 1 1 1 13 Elevatorlift activity Electrical Powersurge Electricalshock, damageto electronic components 3 3 9 Surgeprotectors,grounding systems 1 1 1 14 Elevatorlift activity Electrical Motorfailure Elevatorstuck, occupants stranded 3 2 6 Regularmotormaintenanceand backuppowersupply installation 1 1 1 15 Elevatorlift activity Operational Incorrectweight distribution Overloadingthe elevator, increasedriskof malfunction 2 3 6 Clearlydisplayedweight capacityandmonitoring systems 1 1 1 16 Elevatorlift activity Operational Failuretostop atthecorrect floor Tripping hazards,delayed responseofthe elevator 2 2 4 Regularcalibrationand maintenanceoffloorsensors 1 1 1 17 Elevatorlift activity Human Inadequateuser training Incorrectuseof controls,causing operational errors 2 3 6 Comprehensiveusertraining andclearinstructionalsignage 1 2 2

Table -4: HazardIdentification&RiskAssessmentWorksheet

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page1034 S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 18 Elevatorlift activity Human Lackof maintenance personnel training Incorrect maintenance practices,missed issues 3 3 9 Trainingandcertificationfor maintenancepersonnel 2 2 4 19 Elevatorlift activity Environmental Floodorwater ingress Electrical hazards,elevator malfunction 4 2 8 Properwatersealingand drainagesystems 2 1 2 20 Elevatorlift activity Environmental Earthquakeor structural instability Elevatordamage orcollapse, occupants trapped 5 1 5 Earthquake-resistantbuilding designandstructuralintegrity assessments 4 1 4 21 Elevatorlift activity Mechanical Malfunctionof liftmechanisms Elevatorstall withoccupants inside 4 3 12 Regularmaintenanceand inspectionofliftcomponents 2 1 2 22 Elevatorlift activity Electrical Powerfailure Peopletrapped intheelevator 3 2 6 Backuppowersupply installation 1 1 1 23 Elevatorlift activity Operational Improper operation Misalignment leadingtojerky motion 2 4 8 Stafftrainingandcertification 2 2 4 24 Elevatorlift activity Human Usernegligence Entrapmentor fallaccidents 3 4 12 Clearsafetyguidelinesforusers 2 2 4 25 Elevatorlift activity Environmental Firehazard Elevatordamage andsmoke inhalation 4 2 8 Smokedetectorsandfire extinguishersinstallation 3 1 3 26 Elevator Control Cabinet Maintenance Electrical Hazard Electrical Wiring Exposure ElectricShock, Burns,Injury,or Fatality 5 4 20 ProperElectricalIsolationand Lockout/Tagout 2 2 4 27 Elevator Control Cabinet Maintenance Mechanical Hazard MovingParts Crushingor PinchingInjuries 4 3 12 MachineGuarding 2 2 4 28 Elevator Control Cabinet Maintenance FireHazard Electrical Overheating Fireand PropertyDamage 3 2 6 RegularInspectionand Maintenance 2 1 2 29 Elevator Control Cabinet Maintenance Chemical Hazard Chemical Exposure SkinIrritation, Respiratory Issues 2 1 2 ProperPPEUsage 1 1 1 30 Elevator Control Cabinet Maintenance Ergonomic Hazard Awkward Posture Musculoskeletal Disorders 3 3 9 TrainingonProperLifting Techniques 1 2 2 31 UPSPanel Maintenance Physical ElectricShock Electricalshock tomaintenance personnel resultingin injuryordeath. 5 4 20 Ensureisolationproceduresare followed,useproperPPE. 2 1 2 32 UPSPanel Maintenance Fire ShortCircuit/ Overheating Fireoutbreak damaging equipmentand causinginjury. 4 3 12 Regularthermalscanning, properventilationaroundthe panel. 2 2 4 33 UPSPanel Maintenance Chemical Acid/Corrosive Chemicals Contactwith corrosive substances causingskinor eyeinjuries. 3 2 6 Properlabeling,useof appropriatePPE,andsafe handlingpractices. 2 1 2 34 UPSPanel Maintenance Ergonomic ImproperLifting Techniques Muscularstrain orbackinjuries duringlifting. 3 3 9 Trainingonproperlifting techniquesandusingliftingaids. 2 1 2 35 UPSPanel Maintenance Fire ElectricalFire Fireoutbreak damaging equipmentand causinginjury. 4 3 12 Regularinspectionand maintenanceofelectrical components. 2 2 4

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page1035 S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 36 UPSPanel Maintenance Chemical BatteryAcid Exposure Contactwith batteryacid leadingto chemicalburns. 4 2 8 UseofappropriatePPE(acidresistantgloves,goggles,etc.). 2 1 2 37 UPSPanel Maintenance Fire Overloadingof Circuit Circuit overloading causingfireand equipment damage. 4 3 12 Implementloadmonitoringand powerdistributionchecks. 2 2 4 38 UPSPanel Maintenance Physical FallingObjects Objectsfalling fromheights during maintenance. 3 2 6 Securetoolsandequipment,use safetyharnesses. 2 1 2 39 UPSPanel Maintenance Fire Overheating Batteries Batteries overheatingand catchingfire. 4 3 12 Regulartemperature monitoring,thermalprotection. 2 2 4 40 UPSPanel Maintenance Biological Rodentsand Vermin Infestation Contamination anddamageto electrical components. 3 2 6 Regularpestcontrolmeasures, sealingentrypoints. 1 1 1 41 SlidingDoor Maintenance Mechanical Inadequate Lubrication Slidingdoor jams,difficultto open/close 3 4 12 RegularLubricationand Inspection 2 2 4 42 SlidingDoor Maintenance Operational FaultyLockand Handle Difficultyin securingthe door,potential unauthorized access 2 3 6 RegularInspectionand Maintenance 2 1 2 43 SlidingDoor Maintenance Slip/Trip WetFloordue toCleaning Slipandfall accidents 2 3 6 UseWetFloorSigns,Adequate Drying 1 1 1 44 SlidingDoor Maintenance Chemical Improper CleaningAgents SkinIrritationor Chemical Exposure 3 2 6 UseAppropriateCleaning Agents 1 2 2 45 Sequencing BatchReactors (SBR)Unit Cleaningand InspectionMechanical Moving machineryparts Entanglement andcrush injuries 4 3 12 Engineeringcontrols 3 1 3 46 Sequencing BatchReactors (SBR)Unit Chemical Handling Handling corrosive chemicals Skincontactand chemicalburns 3 2 6 PPE(PersonalProtective Equipment) 2 2 4 47 Sequencing BatchReactors (SBR)Unit Confined SpaceEntryPhysical Limitedspace andpoorair quality Asphyxiationand lossof consciousness 5 2 10 PermittoWorkSystem 3 1 3 48 Sequencing BatchReactors (SBR)Unit Electrical Exposedwires andelectrical shocks Electricshock andburns 3 4 12 Lockout-Tagout(LOTO) 2 2 4 49 Sequencing BatchReactors (SBR)Unit Noise ExposurePhysical Highnoise levels Hearinglossand tinnitus 2 3 6 HearingProtection 1 1 1 50 Sequencing BatchReactors (SBR)Unit ManualLifting -Ergonomic Liftingheavy loads Musculoskeletal injuries 3 3 9 MechanicalLiftingAids 2 1 2 51 Sequencing BatchReactors (SBR)Unit Fireand Explosion Combustible materials Fireoutbreak andproperty damage 4 2 8 FireSuppressionSystem 2 1 2 52 Sequencing BatchReactors (SBR)Unit Slips,Trips, andFallsPhysical Slippery surfaces Slip,trip,andfall injuries 2 4 8 GoodHousekeeping 1 1 1 53 Sequencing BatchReactors (SBR)Unit Confined SpaceEntryPhysical Toxicgas accumulation Poisoningand respiratory problems 4 2 8 VentilationandGasMonitoring 2 1 2 54 Sequencing BatchReactors (SBR)Unit HotWork (Welding, Cutting)-Fire Heatandsparks Fireoutbreak andburns 3 3 9 FireBlanketsandExtinguishers 2 1 2 55 FlowSwitch Maintenance Physical Electricalshock Electrocution 4 3 12 IsolationofPowerSource 2 1 2

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page1036 S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 56 FlowSwitch Maintenance Physical Mechanical injury Crushed fingers/hand 3 4 12 UseofProperPPE 1 2 2 57 FlowSwitch Maintenance Chemical Corrosive chemicals exposure Skinirritation/ chemicalburns 2 2 4 UseofChemicalResistantGloves 1 1 1 58 FlowSwitch Maintenance Ergonomic Awkward posture Musculoskeletal disorders 3 3 9 ErgonomicWorkstationDesign 1 1 1 59 FlowSwitch Maintenance Biological Exposureto harmful microorganisms Infections 2 2 4 UseofPersonalProtectiveGear 1 1 1 60 SolarFencing Maintenance Physical Electrocution fromexposed wiring Majorelectric shockorfatality 5 4 20 Insulatelivewires 3 2 6 61 SolarFencing Maintenance Chemical Exposureto hazardous cleaningagents Moderate chemicalburns 3 3 9 ProvidePPE(gloves,goggles) 2 2 4 62 SolarFencing Maintenance Ergonomic Improperlifting techniques Musculoskeletal injuries 2 4 8 Trainingonproperlifting 2 2 4 63 SolarFencing Maintenance Biological Bites/stings frominsectsor animals Allergicreactions orinfections 3 3 9 Useinsectrepellents 2 2 4 64 SolarFencing Maintenance Psychosocial Work-related stressand fatigue Reducedwork efficiency 2 3 6 Workloaddistribution 1 2 2 65 Replacementof LightBulbs Electrical Electricshock Electricshock leadingtoinjury 4 3 12 Useinsulatedglovesandtools 2 1 2 66 CleaningLight Fixtures Fall Workingat height Fallfromheight leadingtoinjury 3 4 12 Usefallprotectionequipment 2 2 4 67 Testing Electrical Connections Electrical Shortcircuit Firehazard 4 2 8 Regularmaintenanceandtesting 2 1 2 68 Workingin LowLight Ergonomic Poorvisibility Strainortrip hazards 2 4 8 Improvelightingconditions 1 1 1 69 Workingat Heightwith ScissorLift FallHazard Unevenground orsurface Fallfromheight resultingin seriousinjuryor fatality 4 3 12 Ensurescissorliftoperatorsare trainedandcertified 3 2 6 70 Workingat Heightwith ScissorLift Electrical Contactwith livewiresor equipment Electricshock leadingtoinjury orfatality 4 2 8 Ensureproperlockout-tagout proceduresarefollowed 2 1 2 71 UsingTools andEquipment Mechanical Improperuseof toolsor equipment Handorfinger injuriesor equipment malfunction 3 3 9 Providepropertrainingontool usageandmaintenance 2 1 2 72 Workingnear other Personnel Collision Collisionswith otherpersonnel Minorinjuriesor disruptions 2 3 6 Implementclearcommunication andsafeworkzones 1 1 1 73 Workingnear other Personnel Struck-By Struckbyfalling objectsor equipment Headinjuriesor severetrauma 4 2 8 Usebarricadesandhardhats, storematerialsproperly 2 1 2 74 Workingnear Traffic Traffic Proximityto movingvehicles ormachinery Vehiclecollision withworkersor equipment 4 3 12 Setupbarriers,warningsigns, andtrafficcontrolmeasures 2 2 4 75 UseofScissor Lift Tip-Over Scissorlift tippingover Seriousinjuries orfatalitiesdue totip-over 4 2 8 Ensureproperweight distributionandlevelground 2 1 2 76 UseofScissor Lift Entrapment Entrapment betweenlift components Crushinjuriesor asphyxiation 4 2 8 Useliftwithsafetyfeatureslike pinch-pointguards 2 1 2 77 Workingin Adverse Weather Weather Adverse weather conditions Slips,falls,or visibilityissues duetoweather conditions 3 3 9 Monitorweatherconditionsand suspendworkifnecessary 2 2 4 78 Manual Handlingof Equipment Ergonomic Improperlifting andhandling techniques Musculoskeletal injuriesor strains 3 2 6 Providetrainingonproper liftingtechniques 2 1 2

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page1037 S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 79 StormMotor Maintenance Mechanical LackofLockoutTagout Procedure Seriousinjuryto maintenance personneldueto unexpected startup 4 3 12 ImplementLockout-Tagout Procedures 2 1 2 80 StormMotor Maintenance Electrical ElectricShock Electrocutionof maintenance personnel 4 2 8 EnsureLockout-Tagout&PPE Usage 3 2 6 81 StormMotor Maintenance Chemical Exposureto Hazardous Chemicals Chemicalburns orrespiratory issues 3 3 9 UseappropriatePPE 2 1 2 82 StormMotor Maintenance Ergonomic ImproperLifting Techniques Musculoskeletal injuries 2 4 8 Trainingonproperlifting techniques 1 3 3 83 StormMotor Maintenance Fire IgnitionSources Fireoutbreak andproperty damage 3 2 6 Firepreventionmeasures 2 2 4 84 StormMotor Maintenance Workingat Height Fallfromheight Fatalorserious injuries 5 2 10 Fallprotectionequipment 3 1 3 85 StormMotor Maintenance Confined Space Toxic Atmosphere Asphyxiationor poisoning 4 1 4 VentilationandPermitSystems 2 1 2 86 StormMotor Maintenance Noise HighNoise Levels Hearinglossand damage 3 3 9 Usehearingprotection 2 2 4 87 StormMotor Maintenance Fire InadequateFire Exits Trappedinthe eventoffire 3 2 6 Ensureclearandaccessibleexits 1 1 1 88 StormMotor Maintenance Chemical ChemicalSpills Environmental contamination 3 3 9 Spillcontainmentandcleanup 1 2 2 89 DieselEngine maintenance Mechanical Movingengine parts Crushingor trappingfingers 3 4 12 Engineeringcontrols 2 2 4 90 DieselEngine maintenance Chemical Dieselfuel exposure Inhalationof toxicfumes 3 3 9 Personalprotectiveequipment 1 2 2 91 DieselEngine maintenance Electrical Electricalshock Electrocution 4 2 8 Lockout/Tagoutprocedures 2 1 2 92 DieselEngine maintenance Fire Fuelleakorspill Fireorexplosion 4 3 12 Firesafetytraining 2 1 2 93 DieselEngine maintenance Ergonomic Awkward postures Musculoskeletal disorders 2 3 6 Properergonomics 1 1 1 94 DieselEngine maintenance Noise Highnoise levels Hearingdamage 2 4 8 Hearingprotection 1 2 2 95 DieselEngine maintenance Slip/Trip/Fall Oily/greasy surfaces Slip,trip,orfall 3 3 9 Non-slipfloorcoatings 1 1 1 96 Cleaningthe restroomfloor Slips/Trips Wetand slipperyfloor Slipandfall injuries 3 4 12 Useslip-resistantmats 2 2 4 97 Handling cleaning chemicals Chemical Exposureto cleaning chemicals Skinirritationor chemicalburns 2 3 6 Usepersonalprotective equipment(gloves,goggles) 1 2 2 98 Ladderusefor highcleaning Falling Fallingfromthe ladder Brokenbonesor headinjuries 4 3 12 Usestableandproperly maintainedladder 2 2 4 99 Handling restroom waste Biological Exposureto biohazards Riskofinfection 3 2 6 UseappropriatePPE;provide disposalguidelines 1 1 1 100 WallRepair Physical Fallingobjects fromheight Workerhitby fallingtiles 3 3 9 Installscaffoldingandguardrails 1 1 1 101 TilesRepair Chemical Hazardous fumesduring tilecutting Inhalationof toxicfumes 2 4 8 Useproperventilation 1 2 2 102 WallRepair Ergonomic Manualliftingof heavytiles Musculoskeletal injuries 3 4 12 Usemechanicallifters 2 2 4 103 TilesRepair Physical Slips,trips,and falls Workerslipson wettiles 2 3 6 Keepworkareadryandclean 1 1 1 104 WallRepair Biological Moldgrowth duetowater seepage Allergicreactions andrespiratory issues 2 3 6 Repairwaterleaksandimprove ventilation 1 1 1 105 Carpet Shampooing Machine Mechanical Movingparts Entrapmentof bodypartsinthe machine 4 3 12 Ensuremachineguardsarein placeandfunctional 3 2 6

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 10 Issue: 07 | Jul 2023 www.irjet.net p-ISSN: 2395-0072 © 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page1038 S.No Process/ Activity/Work Area RiskCategory Hazard/Aspect (Thesourceof therisk) UnwantedEvent (Risk& Consequence) Inherent Inherent Risk Score Control(s) (HierarchyofControl) Residual Residual Risk Score (S) (L) (S) (L) 106 Carpet Shampooing Machine Chemical Cleaning chemicals Skinirritationor chemicalburns 3 4 12 Provideanduseappropriate PPE(gloves,goggles) 2 2 4 107 Carpet Shampooing Machine Electrical Electrical components Electricshockor short-circuit 4 2 8 Regularinspectionand maintenanceofelectricalparts 2 1 2 108 Handling Chemical Containers Manual Handling Heavylifting andcarrying Musculoskeletal injuriesdueto improperlifting 3 3 9 Providetrainingonproper liftingtechniques 2 1 2 109 SlipperyFloors Slip/Trip Wetfloors Slipandfall accidents 3 3 9 Regularlycleanspillsandputup warningsigns 2 1 2 110 Reception Cobweb Cleaning Physical Slips,Trips,and Falls Fallfroma ladder,Injury 3 4 12 Useoffallprotectionequipment 2 1 2 111 Reception Cobweb Cleaning Chemical Inhalationof Cleaning Chemicals Respiratory Irritation, Poisoning 3 2 6 UseofPPE,AdequateVentilation 2 1 2 112 Reception Cobweb Cleaning Biological Exposureto Mold AllergicReaction, Respiratory Issues 2 3 6 UseofPPE,ProperVentilation 1 1 1 113 Reception Cobweb Cleaning Ergonomic PoorLifting Technique Musculoskeletal Injury 2 3 6 ManualHandlingTraining 1 1 1 114 Reception Cobweb Cleaning Physical EyeInjuries fromDebris EyeIrritation, CornealAbrasion 2 4 8 UseofEyeProtection 1 2 2 115 WaterPond DeepCleaning Physical Slips,Trips,and Falls Workersmay slipandfall 3 3 9 Provideanti-slipfootwearand warningsigns 2 2 4 116 WaterPond DeepCleaning Chemical Exposureto ToxicChemicals Healthissuesdue tochemical exposure 4 2 8 UseappropriatePPE,provide adequateventilation 2 1 2 117 WaterPond DeepCleaning Biological Vector-Borne Diseases Workersgetting infectedwith diseases 3 3 9 Administervaccines,useinsect repellents 2 1 2 118 WaterPond DeepCleaning Physical Drowning Hazards Workersfalling intodeepwater 5 2 10 Implementbarricades,provide lifejackets 3 1 3 119 WaterPond DeepCleaning Physical ConfinedSpace Hazards Workerstrapped inconfined spaces 4 3 12 Followconfinedspaceentry procedures,providegas monitors 2 1 2 120 WaterPond DeepCleaning Ergonomic Musculoskeletal Disorders Strainorinjuries fromlifting 3 4 12 Useliftingequipment,provide trainingonproperlifting techniques 2 2 4 121 WaterPond DeepCleaning Physical Electrical Hazards Electrocutionor electricalburns 4 3 12 Ensurepropergrounding,use insulatedtools 2 1 2 122 WaterPond DeepCleaning Physical FallingObjects Workershitby fallingdebris 4 3 12 Wearhardhats,usesafety netting 2 1 2 123 WaterPond DeepCleaning Chemical Inhalationof Hazardous Fumes Respiratory issuesdueto fumeexposure 3 3 9 Userespirators,ensureproper ventilation 2 1 2 124 WaterPond DeepCleaning Psychological Stressand Fatigue Reduced concentration anddecisionmakingability 2 4 8 Implementwork-restschedules, providepsychologicalsupport 1 1 1 125 PestControl Activities Health Exposureto toxicchemicals Chemical poisoning 4 3 12 PPE-Gloves,Respirators 2 2 4 126 PestControl Activities Safety Slippery surfaces Slipsandfalls 3 4 12 Non-slipflooring 1 2 2 127 PestControl Activities Operational Machinery breakdown Workdisruption 2 3 6 Regularmaintenance 1 1 1 128 PestControl Activities Health Bitesorstings frominsects Allergicreaction 3 3 9 PPE-Protectiveclothing 1 2 2 129 PestControl Activities Health Pesticide residuesonfood Foodpoisoning 4 2 8 Properstorageandhandling 1 1 1 130 PestControl Activities Safety Chemical spillage Environmental contamination 3 2 6 Securetransportation 1 1 1

Fig -2 Distributionofdeterminedresidualriskscores

Thetableprovidedabovepresentsalistofhazardsalong withtheirassociatedriskscores,whicharecalculatedbased onprobabilityandseverityassessments.Thesehazardsare ranked in descending order of risk, with the highest risk score at the top. Topping the list is the hazard related to Vacuum Circuit Breaker Panel Maintenance, posing a significant risk of electric shock due to exposed live parts, potentially resulting in injury or even fatality. Following closely are the hazards associated with Solar Fencing Maintenance,ElevatorControlCabinetMaintenance,andUPS PanelMaintenance,allsharingthesameriskscore,indicating considerabledanger.Thesehazardsinvolvethreatssuchas electrocution,burns,andothersevereinjuries.Toensurea safe working environment, it is imperative that these toprankedhazardsreceiveimmediateattentionandappropriate measuresareimplemented,includingengineeringcontrols, administrativeprocedures,andtheuseofpersonalprotective equipment,toeffectivelymitigatetherisksandsafeguardthe well-beingofmaintenancepersonnelandothersinvolved.

Theproposedcontrolmeasuresaimtominimizetherisk associatedwiththetop-rankedhazards:

1. Hazard: Vacuum Circuit Breaker Panel Maintenance (ElectricShockduetoexposedliveparts)

• ConductRegularMaintenanceInspections:Implementa schedule for regular inspections and maintenance of circuit breaker panels to identify and address any potentialissuesbeforetheybecomehazards.

• ProvideSafetyBarriers:Installphysicalbarriersaround thecircuitbreakerpaneltopreventunauthorizedaccess andaccidentalcontactwithliveparts.

• Use Voltage Detectors: Equip maintenance personnel withvoltagedetectorstoverifytheabsenceofelectrical energybeforecommencingworkonthepanel.

• Implement Restricted Access: Restrict access to the maintenance area to authorized personnel only, and ensurethattheyhavereceivedappropriatetrainingand certifications.

2. Hazard:SolarFencingMaintenance(Electrocutionfrom exposedwiring)

• InstallWarningSigns:Clearlymarktheareasaroundthe solarfencingwithwarningsignsindicatingthepresence ofhighvoltagetoraiseawarenessamongpersonneland thepublic.

• Safe Work Permits: Require a documented safe work permitsystemformaintenancetasksonthesolarfencing toensureproperproceduresarefollowed,andrisksare adequatelyassessedbeforeworkbegins.

• ConductRegularInspections:Regularlyinspectthesolar fencing system to identify damaged or exposed wiring andpromptlyrepairorreplaceanyfaultycomponents.

• ProvideLockableEnclosures:Enclosethesolarfencing systeminlockableenclosurestopreventunauthorized accessandtampering.

3. Hazard:ElevatorControlCabinetMaintenance(Electrical WiringExposure)

• ImplementDoubleVerification:Ensurethatmaintenance activitiesinvolvingelevatorcontrolcabinetsrequiretwo qualified personnel to confirm that electrical isolation and lockout/tagout procedures have been accurately followed.

• Use Non-Conductive Tools: Require the use of nonconductivetoolsduringmaintenancetaskstominimize theriskofaccidentalcontactwithlivewiring.

• Provide Training: Conduct specialized training for maintenancepersonnelonelevatorsystems,emphasizing electricalsafetyprotocolsandprocedures.

• Emergency Procedures: Establish clear emergency responseproceduresincaseofelectricalincidentsduring maintenance, including immediate shutdown and medicalassistanceprotocols.

4. Hazard:UPSPanelMaintenance(ElectricShock)

• PerformRiskAssessments:Conductcomprehensiverisk assessments before performing maintenance on UPS panels to identify potential hazards and implement appropriatecontrols.

• ProvideVoltageIndicators:Equipmaintenancepersonnel with voltage indicators to verify the status of the UPS systembeforestartinganywork.

• Safe Handling of Batteries: If the UPS system includes batteries,ensurethatmaintenancepersonnelaretrained insafebatteryhandlingandwearappropriateprotective gear.

• Establish Safe Work Zones: Establish and clearly mark safe work zones around the UPS panel to prevent unauthorized access and keep personnel at a safe distanceduringmaintenance.

By incorporating these additional control measures, organizationscanenhancetheirsafetyprotocolsandbetter protectmaintenancepersonnelfromtheidentifiedhazards. Regular training, risk assessments, and continuous improvement of safety procedures will contribute to maintainingasaferworkenvironment.Addressingthesetopranked hazards with the appropriate control measures is essentialtoreducetheriskofaccidents,injuries,orfatalities. Byimplementingthesemeasures,organizationscancreatea safer working environment and protect maintenance personnelfrompotentialharmwhileperformingtheirduties. Regulartrainingandsafetyprotocolsenforcementwillalso contributetotheeffectivenessofthesecontrolmeasures

5. CONCLUSION

In conclusion, this research paper presents a comprehensiveandenlighteningexplorationofthehazards and risks associated with Industry 4.0 technology, with a specificfocusonmaintenanceandserviceactivitiesobserved during an industry visit. The visit provided invaluable firsthandinsightsintothepracticalchallengesandpotential dangersthatariseinreal-worldimplementationsofIndustry 4.0.Utilizingtheobservationsmadeduringtheindustryvisit asafoundation,theresearchrigorouslyappliedtheHazard IdentificationandRiskAssessment(HIRA)methodologyto systematically identify and analyze the various hazards encountered.Thisdetailedhazardanalysisallowedforadeep understanding of the safety implications of Industry 4.0 technologiesandprocesses,sheddinglightonpotentialareas ofconcernthatmustbeaddressedtoensurethewell-beingof personnelandthesmoothfunctioningofoperations.

The outcomes of this research underscore the transformative potential of Industry 4.0, which promises increased efficiency, productivity, and technological advancements.However,italsoemphasizestheneedfora holisticapproachtosafety.Thehazardsidentifiedserveas crucialtouchpointsfororganizationsandindustriesseeking toembraceIndustry4.0whilepreservingthesafetyandwellbeingoftheirworkforce.Theproposedcontrolmeasuresand recommendationsoutlinedinthisstudyprovidepracticaland effectivestrategiestomitigateidentifiedrisks.Byadopting these measures, industries can establish robust safety protocols, ensuring a secure and sustainable Industry 4.0 ecosystem that fosters innovation and growth without compromising on the safety of personnel. As Industry 4.0 continuestoshapethefutureofvarioussectors,thefindings from this research serve as a guiding compass for stakeholders, policymakers, and practitioners alike. Implementing the insights gained from this study will be pivotalinnavigatingtheevolvinglandscapeofIndustry4.0 with confidence, prioritizing safety, and building resilient frameworks that foster progress and well-being hand in hand.Throughproactiveriskmanagementandadherenceto best safety practices, Industry 4.0 can truly unleash its transformative potential and create a safer and more prosperousfutureforall.

6. REFERENCES

1. Adem, A., Çakit, E., & Dağdeviren, M. (2020). Occupationalhealthandsafetyriskassessmentinthe domainofIndustry4.0.SNAppliedSciences,2,1–6.

2. Badri,A.,Boudreau-Trudel,B.,&Souissi,A.S.(2018). Occupationalhealthandsafetyintheindustry4.0era: Acauseformajorconcern? SafetyScience,109,403–411.

3. Lee, J., Cameron, I., & Hassall, M. (2019). Improving process safety: What roles for Digitalization and Industry 4.0? Process Safety and Environmental Protection,132,325–339.

4. Leso, V., Fontana, L., & Iavicoli, I. (2018). The occupationalhealthandsafetydimensionofIndustry 4.0.LaMedicinaDelLavoro,109(5),327.

5. Nota, G., Peluso, D., & Lazo, A. T. (2021). The contribution of Industry 4.0 technologies to facility management. International Journal of Engineering BusinessManagement,13,18479790211024132.

6. RIFQI,H.,SOUDA,S.B.E.N.,ZAMMA,A.,&KASSAMI,S. (2020). Lean facility management 4.0: A case study. InternationalJournal,8(10).

7. Tragos, E. Z., Foti, M., Surligas, M., Lambropoulos, G., Pournaras,S.,Papadakis,S.,&Angelakis,V.(2015).An IoTbasedintelligentbuildingmanagementsystemfor ambient assisted living. 2015 IEEE International ConferenceonCommunicationWorkshop(ICCW),246–252.

8. Lu,Y.,Yao,J.,Wang,Y.,&Zhao,Y.(2020).Integrationof IoTandBIMforSmartFacilityManagementinIndustry 4.0.AutomationinConstruction,112,103059.

9. Iorga,B.,Stadtherr,A.,Ganz,W.,&Feldmann,S.(2017). A Review of the Impact of Industry 4.0 on Facility ManagementProcesses.ProcediaCIRP,60,297-302.

10. Alobaidi, R., Almohammed, F., & Choudrie, J. (2020). Integrating Industry 4.0 and Facility Management: A Literature Review. Journal of Facilities Management, 18(4),346-365.

11. Kaeschel, J., Machado, C., & Dröschel, D. (2018). An Industry 4.0 Perspective on Facility Management. ProcediaCIRP,70,303-308.

12. Sundararaj,G.,&Ramachandran,S.(2017).AReviewon theRoleofBigDataAnalyticsinFacilityManagement. ProcediaEngineering,196,1107-1114.

13. Martins, F. A., Ramos, L. F. P., & Leal, R. P. C. (2020). Integrated Facility Management in Industry 4.0: A SystematicReview.Procedia Manufacturing,52,298305.

14. Kim,J.-H.,An,M.-S.,&Lee,J.-H.(2020).Integrationof BIM andIoTforFacilityManagementintheIndustry 4.0 Era. International Journal of Environmental ResearchandPublicHealth,17(7),2305.

15. Grosse,E.H.;Steiner,R.A.(2017)."TheDigitalTwinas EnablerforDigitalTransformation:AConceptualModel forSmartManufacturing."ProcediaCIRP,61,139-144.

16. Hachicha,W.;Gzara,L.;Naudet,Y.;Bouras,A.(2019)."A SystematicReviewofIndustry4.0:State-of-the-Artand Future Trends." International Journal of Production Research,57(7),2053-2075.

17. Al-Faesly, M.; Al-Tahat, M.; Abuelma’atti, M. (2020). "IntegratedFacilityManagementSystemsinIndustry 4.0."ProcediaManufacturing,45,80-85.

18. Rodrigues, E.M.; Carvalho, H.; Araujo, M. (2020). "Industry4.0andFacilitiesManagement:ASystematic LiteratureReview."JournalofFacilitiesManagement, 18(1),2-23.

19. Raaijmakers,L.;Wynstra,F.;Duysters,G.(2020)."The ImpactofIndustry4.0onthePurchasingFunction:A Reviewand ResearchAgenda."Journal ofPurchasing andSupplyManagement,26(4),100661.

20. Georgy,M.;ElMaraghy,W.H.(2021)."DigitalTwinsin the Context of Industry 4.0: A Review." Procedia Manufacturing,52,1012-1018.

21. Baraldi, E.; De Bernardi, P.; Murino, T.; Peretti, U. (2021). "The Role of Facility Management in Smart Manufacturing:ASystematicLiteratureReview."IFACPapersOnLine,54(2),11055-11060.

22. Nascimento, M.C.; Marodin, G.A.; Asif, M. (2022). "Impacts of Industry 4.0 on Lean Manufacturing: A Systematic Literature Review." Journal of Manufacturing Technology Management, 33(2), 540568.