Accident Investigation and Risk Assessment of Failure Mode and Effects Analysis of Overhead Cranes (Case Study: Steel Industry)

Overhead cranes are one of the important lifting equipment in steel factories that have numerous hazards in the workplace and can cause dangerous accidents. In this study, risk assessment was carried out using the Failure Mode and Effects Analysis (FMEA) method. Accident analysis was also carried out using the accident severity and accident recurrence indices of the International Labor Organization (ILO). The number of employees in the unit was 152. Based on the FMEA analysis, 45 hazards were identified, of which 6 were acceptable and had low risk, 30 were medium risk, and 9 were high risk. The number of accidents during the study period was 27, of which 25 were minor accidents and 2 were severe accidents, and there were no very severe accidents. The highest accident recurrence index was 68.100 in Bahman. The accident severity index was 0.38 in Khordad and 0.009 in Bahman. The results showed that 44.44 percent of accidents involved employees with 1-3 years of work experience and 55.55 percent involved injured workers aged 31-45. 62.96 percent of accidents occurred between 7:00 and 16:00. The most severe body injuries were in the upper limbs, 36.36 percent of the injured.