RISK ANALYSIS OF MISMANAGEMENT IN

THE METAL CASTING PROCESS AT PT

PINDAD USING THE HIRARC METHOD
Abstract
The metal casting process is one of the methods in making products available in the Support
Production Department of PT Pindad. The high level of risk of work accidents in the metal casting
process requires the application of occupational health and safety. The HIRARC method is a method
for preventing or minimizing work accidents which contains a combination of hazard identification,
risk assessment, and risk control or hazard assistance, risk assessment, and risk control. The research
conducted included in the quantitative research by collecting data through observation,
documentation, questionnaires, as well as interviews conducted with company representatives. Data
were analyzed using the HIRADC (Hazard Identification, Risk Assessment, and Determining Control)
method and the risk assessment matrix refers to SHE Risk Management with the inclusion of
suggestions for improvements to the company. The results of the study found the types or sources of
hazards that could pose a risk of work accidents, namely physical hazards including fire, noise,
residual dust, hot metal, and falls.
Keyword: Risk, Metal, HIRADC, and Work
1. INTRODUCTION with temperatures ranging from 800
°C to 1600 °C are frequently created
One of the state-owned firms, in their application at PT Pindad.
PT Pindad is a manufacturer of
industrial equipment as well as The metal casting technique
equipment for military and security used by the PT Pindad Support
(State-Owned Enterprises). Weapons, Department produces a wide range of
ammunition, combat vehicles, and items, including parts for heavy
other weapon system equipment are machinery, automobiles, and fire
among the military and security items leveling equipment. At PT Pindad, the
that have been created during the production process employs the metal
production process. Along with casting method through a number of
creating industrial goods including operations, including the creation of
machine tools, generators, forging and models or patterns. Once the model or
casting products, building and pattern has been created, it can be
construction goods, mining and molded or, if a mold is available, it
agricultural goods, and other ordered can be smelted and filled with metal
goods. liquid. After the metal liquid has been
poured into the mold, it can be
One of the processes used in disassembled so that the casting
the Support Production Department of product can undergo shootblasting and
PT Pindad to create products is the fettling finishing.
metal casting process. Making a
product by melting solid metal and
pouringitintoa mold cavity is known
as metal casting. The metal casting
technique is typically used to create
products that cannot be created
through the machining process, have
complex curves and shapes, and call
for products that meet certain material
requirements. Cast iron, steel,
aluminum, brass, and other materials
The company cannot be protected from the
risk of work accidents given its work structure.
The operationalization that results from the
company's internal and external environments
increases the danger of work accidents in the
practice system (Aljabi, 2020). According to
data from BPJS Ketenaga Kerjaan (2022), in
2019 there were 182,853 work accidents, then
in the following year it climbed by 21.28% to
221,740 instances, then in 2021 it again
increased to 234,270 cases. The same applies
to PT Pindad. Table 1.1 lists the work dangers
that have occurred in the metal casting process
during the past three years based on corporate
data.

Tabel 1. 1. Kejadian Kecelakaan pada PT Pindad

No Tahun Dep Sub Bagian cedera

1 2019 Cast Tube Genitals
2 2019 Cast Furan & inti Upper arm near the left shoulder
3 2019 Cast Fettling The sole of the right foot is punctured by
casting material
4 2020 Suport Subprod-2 The little finger of the right hand is pinched
by the ms lasco claw until it is torn there is a
fracture/fracture of the bone
5 2020 Suport Fetlling Eyes hit by slipper gram splashes
6 2020 Suport Disa The thumb of the left hand was hit to a deep
tear 2 cm long the fingertip bone cracked
7 2021 Suport Fetling Little finger of the left hand
8 2021 Suport Fetling The thumb of the left hand (thumb)
9 2021 Suport Fetling Eyes hit by gram slep reflections
10 2021 Suport Fetling Eyes hit by gram slep reflections
11 2021 Suport Tempa Right hand punctured by knife trimming ples
material

The high level of risk of work management systems is OHSAS 18001:2007.

accidents in the metal casting process requires
the application of occupational health and
safety. Due to the impact of this work
accident, it can result in workers getting
injured and even death if not handled properly.
This condition can harm not only the
workforce (employees), but also the company,
both directly and indirectly.
Doing an examination of the potential
for risk in the metal casting process is one
technique to achieve this. According to the
observations, there are a number of possible
dangers and hazards in each current production
flow that could lead to workplace accidents.
There are many methods for identifying
dangers in the workplace, including
inspections, statistics on work accidents,
illnesses, and attendance, reports from the K3
team and P2K3, supervisor and employee
complaints, industry expertise, material safety
data sheets, and others.
One of the international standards for
implementing occupational health and safety
OHSAS 18001 states that K3 management is
an integrated effort to manage the risks that are
present in the company's operations and have
the potential to cause human injury, property
damage, or a disruption of the company's
business. By implementing OHSAS 18001, the
organization has a clear frame of reference for
K3 management effectiveness, including the
monitoring of management failures and the
detection of hazards emerging from the
production process.
The HIRARC Approach, according to
Nurmawanti (2013), combines hazard
identification, risk assessment, and risk control
in order to prevent or minimize workplace
accidents. A risk assessment and risk control
will be implemented to lessen exposure to the
dangers present in each form of work after
determining the type of work activity that is
then identified as the source of the danger in
order to acquire the risk value. So that the final
results of this study are expected to help the
company in identifying the types of hazards
 that can occur in the metal foundry production
area of PT Pindad, assess the risks, and be able
to control the risks of hazards that may occur.
2. LITERATURE REVIEW
OCCUPATIONAL SAFETY AND
HEALTH
A condition when there are no risks
associated to environmental hazards is known
as occupational safety and health. K3 is
defined scientifically as an effort to apply
research to prevent occupational diseases and
accidents that are brought on by the workplace
and its environment.
Occupational safety has principles to
ensure the safety of everyone in the work
environment, manage and maintain production
sources for efficient and safe use, and provide
protection for workers from various factors
that affect safety and health (Redjeki, 2016).
Occupational safety and health have a
scope that companies must pay attention to
according to (Setyawan, 2020) including:
1) Working Environment
The setting in which employees
perform their duties is referred to as the
workplace. To reduce the likelihood of
probable accidents and occupational disorders,
environmental variables such as temperature,
lighting, situation, and ventilation must be
accommodated.
2) Work tools and materials
Any equipment and supplies utilized
during work to process goods and services are
referred to as tools and materials. Materials
and working tools have a determining role in
the production process. In this instance, it is
necessary to adhere to the completeness and
working circumstances.
3) Working methods
Work techniques are established rules
or procedures for work that are tailored to the
task at hand. Standards can aid in the efficient
and effective implementation of activities to
ensure occupational safety and health. As an
illustration, consider how something might use
personal protection equipment and machinery
that operate in accordance with standards.
OCCUPATIONAL ACCIDENTS
Workplace accidents are unforeseen
occurrences. While it is not predicted because
the event that occurs has the potential to
produce material or non-material losses on a
light or to the most severe scale, it is referred
to as unexpected since it lacks an element of
planning and intentionality. Accidents at work
can happen as a result of human interaction or
contact with materials, tools, the environment,
or energy sources like chemicals, noise, high
temperatures, machinery, electricity, and so on
that are at levels above what the human body
can tolerate. so that mishaps like burns,
fractures, wounds, and other diseases of the
body's physiological activities can happen.
CAUSES OF WORK ACCIDENTS
Environmental variables, dangers,
equipment and equipment, and human factors
are the four elements that might influence and
interact in every work accident. Workplace
accidents can often be categorized as having
two causes, among others. 2014 (Triyono)
1) Unsafe Action
Unsafe activity is anything that could
lead to work accidents that result in financial
loss, physical harm, or even death. It is
believed that human conduct at work leads to
unsafe actions.
2) Unsafe condition
The work environment is everything
that surrounds employees as they perform
various duties for which they are paid.
Conditions from the workplace that have the
potential to raise the risk of accidents are
known as unsafe circumstances.
DANGEROUS
Danger is everything including actions
or situations that have the potential to cause
human injury or accident, damage, or other
disturbances (Natarisa et al., 2016). The
danger that occurs requires control efforts so
that the impact caused by the danger is not
large and detrimental.
The following is a classification of
hazard types according to (Aprilliani et al.,
2022):
1) Mechanical Hazards
A mechanical danger is one that
results from mechanical motion in tools or
other items. Both manual and driven-driven
motions can provide mechanical force. Lathes,
burrs, cutting devices, presses, and several
other machines are a few examples.
2) Electrical Hazards
Electrical energy is a source of danger
that can result in electrical hazards. Because
the power grid serves as the energy source for
all commonly used tools and equipment,
electrical energy can be found in a variety of
work environments. electrical risks that can
happen, including fire, shock, electric shock,
and more.
3) Chemical Hazards
Chemical hazards come from the
properties and content of the chemicals. In
various industries chemicals are commonly
used to support the process. It is not
uncommon for chemicals to have harsh
properties that are harmful to humans.
4) Physical Hazards
Physical hazard is a danger that comes
from physical factors such as gas, noise,
temperature, lighting, radiation of radioactive
materials, vibration, and so on.
RISK ANALYSIS
Risk is the likelihood that an event
will take place. The risk in K3 is connected to
the risk of traumatic incidents that affect
conditions related to health and safety. Hence
that risk management is needed which is
referred to as risk management (Triyono,
2014).
Risk is the representation of
prospective dangers that could happen and
have a range of severity and frequency. The
management employed determines the impact
produced. Risk levels might range from the
least to the most serious. In order to limit and
control potential hazards and risks and prevent
losses, it is necessary to analyze and evaluate
prospective risks.
Risk can be calculated based on the
likelihood that an event will occur and the
consequences that will result if it does. The
value of the risk, often known as the risk, must
therefore be considered. Risks can, however,
have positive effects in addition to unfavorable
ones.
RISK MANAGEMENT
K3 risk management is an effort
undertaken for K3 risk management aimed at
averting undesirable incidents through a more
well-planned and structured approach
(Setyawan, 2020).
To reduce potential effects, risk
management is a process that is used in
response to known dangers. Risks must
therefore be precisely defined and then dealt
with through active strategies and procedures.
Planning, risk identification and analysis, risk
assessment, risk handling, and risk monitoring
are all included in risk management.
3. METHODOLOGY
STAGES OF RESEARCH
This research is categorized as a
descriptive quality research that aims to
analyze the risk of work accidents referring to
work activities at PT Pindad using the
HIRARC method. The following are the stages
of the research carried out, found in figure 1.1.
 Gambar 1. 1 Diagram Alir Penelitian
(Sumber: Penelitian, 2022)
DATA COLLECTION PROCESS
In-depth interviews with business
representatives, direct field observation, an
examination of operational procedures, and
other methods were used to acquire the data
for this study. The descriptions of each study
technique are provided below.
1. Observation
A research method known as
observational research involves the researcher
observing subjects and events in their most
natural environments. This enables the
researcher to observe the subject normally.
The outcomes of the observation will serve as
the foundation for valuable data that
academics may then evaluate and compare
with the papers that are currently available.
2. Interview
Interviews are used to guide the
researcher as he or she asks respondents
questions and answer choices. Interviews were
conducted with a guide to the list of questions
that the researcher would read to respondents.
In quantitative interviews, consistency in the
way questions and answer options are
presented is essential.
3. Document Analysis
The documents required for the
research are official documents of PT Pindada
which contain an overview of the company,
 then also standard opetional procedure (SOP)
documents and also identification of potential
hazards and risks, HIRA record data and
various other documents.
RESEARCH METHODS AND DATA
ANALYSIS
1) Research Method
Descriptive qualitative research is one
of the research methodologies that is
consistent with the study topic. In qualitative
research, non-numerical data (such as text,
video, or audio) is gathered and analyzed to
better comprehend concepts, opinions, or
experiences (Fauzy, 2019). It can be utilized to
uncover complex insights regarding a situation
or to spark fresh research concepts. The
phenomena of occupational safety and health
in PT Pindad's metal casting activities and
their description in accordance with the
identification, assessment, and risk analysis
are understood and explained through
qualitative research.
2) Data Analysis
K3 Risk Management is referenced in
the data analysis utilizing the HIRADC
(Hazard Identification, Risk Assessment and
Determining Control) study form and the risk
assessment matrix. An assessment of the
current situation will be made in the study, and
the results will be compared with observations
made by identifying hazards and controlling
the necessary risks. The actions are listed
below.
3) Risk Identification
Risk identification is carried out to
analyze the K3 risk that occurs in metal
casting activities based on the company's
HIRARC and compare with actual production
activities then the results are also supported by
existing literature.
4) Risk Assessment
Identified hazards will be collected
and checked from interviews, observations,
and documents obtained. After that, it will be
compiled in the form of a report using the
HIRARC method in accordance with existing
standards.
5) Risk Control
Furthermore, risks that have a high
level of assessment will be controlled referring
to the hierarchy of risk control.
6) Proposed Improvements
Researchers will provide proposed
improvements that are felt to be lacking and
can be developed further than what exists
today.
4. FINDINGS AND DISCUSSION
IDENTIFICATION OF THE
PRODUCTION PROCESS OF THE
METAL CASTING DEPARTMENT
It is crucial to identify the
manufacturing process in order to determine
the order in which the metal casting
production activities at PT Pindad are carried
out. From this production activity, we can then
examine the different types of dangers that are
there. The findings of observations and
interviews with a number of on-duty personnel
were used to compile data on the identification
of the production process.
HAZARD IDENTIFICATION
In the process of producing metal
castings, PT Pindad does hazard identification.
The outcomes of the hazard identification
process will next be used to determine the
danger's source, type, and factors, which can
be broken down into three categories: people,
objects, and the environment. Acquired at PT
Pindad includes seven workstations, each with
a set of sequential tasks. Based on job
activities, several danger kinds are identified,
and the source of the hazard is then examined.
According to the source, there are four
different categories of contemporary dangers.
The four categories of risks that are mentioned
in this study are explained as follows:
1) Physical Hazards (P)
Physical hazards are potential hazards
stemming from physical factors such as hot
rooms, dust exposure, dehydration, and
irritation.
2) Mechanical Hazards (M)
Mechanical hazard is a potential hazard
originating from a moving object or process
that causes the impact of being cut, impacted,
punctured, scratched, fallen, pinched, and cut.
3) Chemical Hazards (C)
Chemical hazards are potential hazards
sourced from chemicals in the form of gases,
solids, and liquids that have flammable,
explosive and corrosive properties.
4) Electrical Hazards (E)
Electrical hazards are hazards that originate
from electricity and can cause stuns, burns,
and death.
RISK ASSESSMENT
A risk assessment process will be used
to establish the risk level after possible risks in
each job activity have been identified. During
section K3 interviewing, risk assessments
estimated to ascertain the likelihood and
consequent severity of each hazard risk were
carried out. Two key factors will be taken into
account when assessing risk: probability
Tabel 1.2 Probability Level Assessment (O)
Possibility (O)
Often
Frequent weekly
Rather often (monthly)
Rarely annual
May occur
Source. (Natarisa dkk., 2016)
RISK CONTROL
The risk assessment findings will
serve as the foundation for choosing control
measures to remove or lower the level of risk
posed by existing risks. There are five methods
for risk control overall at OHSAS 18001: 1)
Elimination, 2) Replacement, 3) Engineering
control, 4) Administrative approach, and 5)
Personal Protection Equipment (PPE). Risk
management for metal casting production
activities was done by PT Pindad.
According to the results of the risk
management, PT Pindad has only implemented
three controls that are used in the metal casting
production process. This is due to the fact that
the process activity cannot be substituted for;
doing so would result in a product of worse
quality than intended.
5. CONCLUSION
The following are the conclusions of the
research that has been carried out:
(occurrence) and consequences (severity) as
part of the level to establish the potential
severity of the risk. . Risk analysis aims to
determine the amount of risk so that it can then
be ranked and sorted out the risks that have a
big impact to pay attention to and the risks that
have a small impact can be ignored. The
results of the risk assessment are used for
evaluation and comparison with predetermined
criteria to determine whether the risk is
acceptable or not. If the risk is unacceptable,
management is needed to reduce the impact.
The assessment of the degree of probability is
shown in table 1.2
Description Score
Continous
5
80 – 100%
20 – 40
times/year 4
60 – 80%
11 – 20
times/year 3
40 – 60%
1 – 10 times/year
2
20 – 40%
<1 times/year
1
0 – 20%
1) 1) Research found that there are several types
or sources of hazards that can pose a risk of
work accidents in the metal casting process at
PT Pindad consisting of 28 types of physical
hazards, 10 types of chemical hazards, 1 type
of electrical hazards, and 31 types of
mechanical hazards.
2) 2) The risk value contained in the metal
casting process at PT Pindad found that there
is no source of danger that has a high level of
risk with a score of 23-25 in the metal casting
process, then for a strict risk level with one
number, namely at the source of danger of
rotating objects, the conditional risk level of
27 sources of danger, including the source of
fire hazard, electric current, chemicals, sharp
objects, noise, residual dust, hot metal,
dropped, pinched, hit, and crushed by material.
3) Appropriate risk control measures in the metal
casting process at PT Pindad have been given
control proposals at each source of hazard. At
the source of fire hazard with the amount of
risk 1 and conditionally with engineering
control the installation of a fire alarm that will
automatically release water when detecting a
fire. The source of danger of electric current is
carried out engineering control by giving a
cover to the cable so as to avoid the electric
current being exposed. Rotating objects with a
strict level are carried out Engineering control
by setting a protector on the rotating machine
and also sensors to detect abnormalities. So
that if the engine rotates abnormally, the
engine will immediately stop.
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