Productivity and Quality in Smart Manufacturing Systems

Hazard Identification and Risk Control in Rotary Kiln Within The Cement Manufacturing Company

Afrigh Fajar Rosyidiin, Moses Laksono Singgih and Patdono Suwignjo


This paper presents the situation of a cement manufacturing sector company. The company has implemented work safety regulations and programs, but the problem of work accidents will always be an unexpected threat. Several aspects of work accidents occur due to unsafe actions and unsafe conditions. A rotary kiln is an area that has a high potential for danger because the process requires high temperatures, chemical reactions, and rotating machines. So in this study carried out identification of hazards and risks that occur and repaired work problems using Hazid Methodology. Used hierarchy of control to provide proposals for risks with a very high level, While the risk matrix determines the risk level mapping. Hazard identification is carried out using Electrical, Mechanical, Physical, Chemical, Biological, Ergonomic, Psychosocial, Environmental hazards, Natural phenomena, Locative. The results of the hazard identification are 25 hazards and 40 risks. There are 35% very low, 20% low, 35% moderate, 5% high, 5% very high at the risk mapping level. The proposed improvement for two risks with a very high level is Co-processing to replace coal
with solid waste and replace clinker with fly ash.

Keywords: Rotary Kiln, Hazid Methodology, Risk Matrix, Hierarchy of Control



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