Enhancing Safety Measures in a Steel Manufacturing Facility; Factory X Case Study

Productivity and safety of the workers have been issues in most manufacturing facilities in Egypt and all over the world, as the main aim of any manufacturing facility is to increase profit and limit costs as much as possible. Through analysis and simulation, this paper aims to create a safe workplace for the worker; risk assessment and Failure Mode and Effect Analysis (FMEA) and the basics of the international standards ISO 31000 and ISO 45001 have been conducted to evaluate different hazards and potential risks. Moreover, lean tools such as 6S and Visual Management are proposed solutions to enhance workplace safety and decrease the possibility or severity of potential risks. Therefore, a new workplace design, an example of a high-level hazard in industry in Egypt's local market, has been established for the steel manufacturing facility under consideration using Sketch Up. The results of the proposed solutions, such as new frameworks, worker safety training, equipment replacements, and applying lean tools, have shown a practically acceptable percentage of safety improvements and a decreasing risk priority number (RPN). The percentage decrease for (RPN) ranges between 31.43% to 90.47% for different potential risks.