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Paper ID:IJSREM66415

HAZARD IDENTIFICATION AND RISK CONTROL FRAMEWORK FOR ROLLING MILL MANUFACTURING PROCESSES

Stream/Area:

-

Subject:

-

Paper ID:

IJSREM66415

Volume:

10 |

7 |

Jul 2026

Pages:

1-9

Publication Frequency:

Monthly (12 issues per year)

DOI
Digital Object Identifier
10.55041/IJSREM66415

License:International Journal of Scientific Research in Engineering and Management follows the Creative Commons Attribution 4.0 (CC BY 4.0) License, allowing free use and distribution with proper attribution.

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Authors

PT

Princ Tripathi

FIRE TECHNOLOGY & SAFETY ENGINEERING

VIKRANT UNIVERSITY, GWALIOR

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PVT

Prof. Vishal Tiwari

FIRE TECHNOLOGY & SAFETY ENGINEERING

VIKRANT UNIVERSITY, GWALIOR

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Abstract

Rolling mill manufacturing is one of the most critical operations in the steel industry due to the presence of heavy rotating equipment, high-temperature materials, hydraulic systems, cranes, electrical installations, and continuous production processes. Workers are exposed to hazards such as entanglement, crushing, burns, explosions, falling materials, electrical shock, excessive noise, and ergonomic stress. Traditional safety practices often focus on incident response rather than proactive hazard identification and systematic risk control. This study proposes a Hazard Identification and Risk Control Framework (HIRCF) for rolling mill manufacturing processes that integrates Hazard Identification and Risk Assessment (HIRA), Failure Mode and Effects Analysis (FMEA), Bow-Tie Analysis, Job Safety Analysis (JSA), and the Hierarchy of Controls within the ISO 45001 Occupational Health and Safety Management System. The framework identifies major operational hazards, evaluates their associated risks using a risk matrix, prioritizes corrective actions, and establishes engineering, administrative, and behavioral controls. The proposed framework supports continuous monitoring through key safety performance indicators and digital technologies, enabling steel industries to reduce accidents, improve operational reliability, and strengthen regulatory compliance.

KEYWORDS

Rolling mill Hazard identification Risk control HIRA FMEA Bow-Tie Analysis ISO 45001 Occupational safety Steel manufacturing.

Cite This Article

Princ Tripathi, Prof. Vishal Tiwari, "HAZARD IDENTIFICATION AND RISK CONTROL FRAMEWORK FOR ROLLING MILL MANUFACTURING PROCESSES," International Journal of Scientific Research in Engineering and Management, vol. 10, no. 7, pp. 1-9, Jul 2026. https://doi.org/10.55041/IJSREM66415

Full Article/Conclusion

Rolling mill manufacturing involves complex mechanical, thermal, electrical, and material handling hazards that require a structured and proactive approach to risk management. The proposed Hazard Identification and Risk Control Framework integrates established risk assessment techniques with engineering controls, behavioral safety, and digital technologies to improve occupational safety and operational performance. By systematically identifying hazards, prioritizing risks, implementing effective controls, and monitoring performance through measurable indicators, steel plants can significantly reduce accident potential and enhance sustainable manufacturing. Future research should validate this framework across multiple rolling mill facilities and explore advanced predictive analytics for dynamic risk assessment.

References

1.                Bird, F. E., & Germain, G. L. (1996). Practical Loss Control Leadership. Det Norske Veritas. 2.                Goetsch, D. L. (2021). Occupational Safety and Health for Technologists, Engineers, and Managers. Pearson. 3.                Heinrich, H. W. (1931). Industrial Accident Prevention: A Scientific Approach. McGraw-Hill. 4.                International Organization for Standardization. (2018). ISO 45001: Occupational Health and Safety Management Systems—Requirements with Guidance for Use. 5.                International Organization for Standardization. (2019). ISO 31000: Risk Management—Guidelines. 6.                Reason, J. (1997). Managing the Risks of Organizational Accidents. Ashgate. 7.                Occupational Safety and Health Administration. (2023). Machine Guarding (29 CFR 1910 Subpart O). 8.                Occupational Safety and Health Administration. (2023). Control of Hazardous Energy (Lockout/Tagout) (29 CFR 1910.147). 9.                AIChE Center for Chemical Process Safety. (2021). Guidelines for Risk Based Process Safety. 10.             International Labour Organization. (2022). Safety and Health at Work.

Editorial & Review Transparency

Publication Date

7/30/2026

Peer Review Type

Double-Blind Peer Review

Review Rounds: 2

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