Monitoring and Identifying Occupational Health and Safety Risks in Various Foundry Processes Using the ELMERI Method

Accident rates are notably high in industrial metalworking processes. This study aimed to identify and manage occupational health and safety (OHS) risks using the ELMERI observation method to minimize workplace accidents within a foundry operating in the metalworking sector. A quantitative case study was conducted, during which the foundry was monitored quarterly over the course of 1 year. For each of the processes considered—melting, molding, casting and thermal process—1800 observations were made, culminating in a total of 28,800 observations by the end of the year. The average safety index was calculated for each department, and the variability in OHS risks throughout the year was analyzed on a departmental basis. In calculating the safety index, seven key criteria from the ELMERI scale were emphasized, as follows: safety behavior, order and tidiness, machine safety, industrial hygiene, ergonomics, floor and access ways, and first aid and fire safety. Assessing the level of safety in these processes based on these criteria provides a strong foundation for effectively analyzing and managing OHS risks. This case study demonstrates that the periodic application of the ELMERI scale in foundries characterized by hazardous work environments is a valuable tool for managing fluctuating OHS risks.