Analysis of Occupational Safety and Health in the Production Process Section Using the Failure Mode And Effect Analysis ( FMEA ) Method at PT Mitra

DOI: 10.31284/j.iptek.2021.v25i1.11 78 Based on the results of the analysis carried out, it was found that there were 29 work accidents in the turning wood production process for a period of 3 years, then after the classification was carried out based on the company's working environment conditions obtained 5 categories of work accidents. The results of the calculation of the risk prority number (RPN) show that the potential failure with the highest RPN level is that the hand is exposed to wood on the rip saw machine with an RPN value of 140. Proposed improvement is that machine operators must use PPE when doing work, provide a grace period when moving raw materials to rip saw machines to provide space for workers, routine inspections and always moving materials after being processed in the rip saw machines and giving danger signs in the production process area, improving standard operational procedures and periodic supervision in accordance with the applied K3 procedures.


INTRODUCTION
PT. Mitra Mandiri Perkasa is a manufacturing company engaged in wood processing which is processed into turning wood products. As an active company, of course, there are problems, both internal and external, which include problems regarding occupational safety and health risks. Companies must have a good system in managing risks so that they can minimize the occurrence of risks in every production activity [1]. Risk is the chance of something happening that has an impact e-ISSN:2477-507X Vol.25 No.1,Mei 2021 28 on the objectives measured in terms of consequences and probabilities [2]. A risk is an event that arises as a result of an error or negligence while working which results in consequences and uncertainty [3].o reduce or minimize risk, it takes time from an effective and efficient strategy, so that the minimum risk that occurs can be avoided [4]. If there is a level of consequence, it is necessary to have research to analyze the occurrence of occupational risks. The Failure Mode and Effects Analysis (FMEA) method is used to identify potential hazards of work accidents and to measure the level of risk that may occur as a result of these accidents [5].Lack of awareness in maintaining safety while working in the production department greatly affects productivity and the high number of work accidents. Machine operators who do not use personal protective equipment (PPE) and do not comply with standard production work operation regulations are the dominant factors in the occurrence of work accidents in the production division.
To reduce the occurrence of work accidents, good control is needed on all activities of the production process, matters related to risks must be avoided and minimized. The results of the analysis using the FMEA method are to determine the potential risks that could potentially occur during the turning wood production process at PT. Mitra Mandiri Perkasa. The purpose of this study is to identify the risk of causing work accidents in the turning wood production department, to carry out a risk assessment of work accidents using the FMEA, and to formulate preventive actions that can be taken by companies to reduce the level of risk of accidents at work.

LITERATURE STUDY
A work accident is an incident caused by an error committed by a worker, damage to tools and machines that can result in injuries to workers [6]. To minimize damage due to work accidents, hazard risk mapping can be carried out to anticipate work accidents [7]. FMEA is a method that identifies and measures in a structured manner to prevent potential failure of a process [8]. FMEA is used to determine and identify activities of an operational nature as well as to mitigate risks which are measured using the Risk Priority Number (RPN) [9].
The stages and steps of the FMEA method used are (a) Identifying categories of work accidents that occur during the production process in a section (b) Determining the value of the seriousness or severity due to work accidents (c) Determining the Occurance value or the level of the frequency the occurrence of an accident (d) Determine the value of the detection or the possibility of an error occurring or the impact of an error. (e) Calculation of RPN to determine priority actions that must be taken. The Risk Priority Number is a multiplication of severity, occurrence, and detection. (RPN = severity x occurrence x detection), (f) Determining recommendations for potential failures from the highest RPN value, (g) Doing solutions to the RPN value in the form of suggestions and improvements.
The severity rating is a rating related to the severity of the effect caused by the failure mode. The directing effect can be rated on a scale of one to ten, with ten being the most severe. After the severity value, occurrence and detection is obtained. Then calculate the value of the risk priority number by multiplying the values of the severity (S), occurrence (O), detection (D). This RPN value will be used as material for analysis and corrective actions to reduce and improve standard work procedures in the turning wood production process.

RESEARCH METHODS
This research was conducted at PT Mitra Mandiri Perkasa, a company engaged in the manufacturing industry that produces processed wood in the form of Turning. Where in the production process, PT Mitra Mandiri Perkasa still often finds problems in the form of work accidents that occur in every environment in the production site. This research begins with the first step to identify work accident data in the turning wood production process. The work accident data used is from 2018 to 2020. From the work accident data, it can be seen the causes of work accidents, types of accidents, their impact, and the frequency of accidents that occur. The second step is to classify the types of work accidents into several categories, namely due to negligence of workers, damage to equipment, and damage to machines, as well as due to environmental conditions in the workplace. After the classification of work, accidents are carried out, the third step is to compile a questionnaire to obtain severity, occurrence, and detection values, the questionnaire is given and filled in by the company's K3 team which is responsible for the identification and analysis of work accidents in the production department. After obtaining the Severity, Occurrence, and Detection values, the fourth step is to calculate the Risk Priority Number value. The results of this calculation are then used as a ranking or ranking to obtain the highest RPN value as a proposed improvement step that will be carried out to reduce the occurrence of work accidents.

RESULT AND DISCUSSION
Based on the results of collecting data on work accidents in the turning wood production process in 2018 to 2020, data on the causes of accidents, types and impacts of the occurrence of work accidents can be obtained. Work accident data is presented in The pile load of material on the pallet is irregular so that the wood falls when it is lifted using a forklift The wood fell when lifted Scuffed feet 3 Incident 3 The process of moving material using a forklift is not careful enough so that the wood falls on the workers

Sum of incidents 28 Incident
From the table above it is known that there were 28 work accidents. Furthermore, these types of work accidents entirely occurred in the production department at PT Mitra Mandiri Perkasa. From these results, work accident categories will be identified and carried out according to the real conditions of the company. The results of the work accident category adjusted to the company's work environment are shown in the table below.

Tabel 5. Occupational Accident Category Based on Company Work Environment Conditions No
Work Accident Category Explanation 1 Contact with a moving machine or material in the machine This category is a work accident that occurs due to contact or interaction with production machines while working or contacts with material (in the machine) when the machine is operating.
2 Hit by a moving vehicle This category is a work accident that occurs due to being hit by a vehicle in a factory such as a forklift. 3 Being hit by a moving, flying, or falling object This category is a work accident that occurs due to a collision between the victim and an object that is in an unstable/flat position so that the object falls and hits the victim. 4 Slip, trip, and fall at the same height This category is a category of work accidents that occur because the victim slips, trips, falls. because the floor conditions are uneven, wet, slippery or perforated. 5 Getting hurt while handling work, lifting things, or carrying them This category is a general category of work accidents that often occur in companies. Especially when the victim is handling the work at hand. Based on the table above, it can be seen that there are 10 categories of work accidents in PT Mitra Mandiri Perkasa, whereof these types of work accidents generally often occur due to errors and negligence of workers. The following are pictures of some examples of workers' activities while doing Turning wood production work.
(a) (b) Figure 1.a) the distance between workers close together without using PPE, b) Workers cut wood with a jigsaw with their feet on the wood Source: PT MitraMandiri Perkasa Turning wood production process From the picture above, it can be seen that workers do not wear PPE in the form of shoes and head protection helmets when doing work on molding and wood cutting machines where can have the potential for work accidents to these employees. After obtaining the occupational accident categorization, then measuring the scale of severity, Occurrence, Detection as shown in the following table. The respondent who gave the assessment was the supervisor of the production department who is a member of the company's K3 group who has received training and understands the potential hazards that occur in the production department. Based on the results of the RPN calculation above, it can be seen that the one with the highest RPN value is from the Potential Failure Mode, namely, the hand is exposed to wood on the rip saw machine with a branch value of 140. From the results of the above calculations, then priority actions will be taken to prevent this type of accident. The causes of this type of work accident when workers' hands are exposed to wood on the rip saw machine is not wearing PPE, unfocused and negligent, narrow space or, no danger signs on machines, no periodic cleaning after completion of work and equipment and work processes are not conformity and lack of oversight.
Suggestions for improvement that can be proposed are that the head of the production sector gives a warning to workers on the importance of using PPE when doing work, Provides delay time, and turns when moving raw materials to the rip saw machine so as to provide space for workers, routine inspections and always moving materials after processing in the rip saw machine and giving a danger signal to the machining facility, carry out tighter supervision in accordance with the applied PPE procedure.

CONCLUSION
Based on the results of the analysis carried out, it was found that there were 29 work accidents in the turning wood production process for a period of 3 years, then after the classification was carried out based on the company's working environment conditions, there were 5 categories of work accidents. The results of the calculation of the risk priority number (RPN) show that the potential failure with the highest RPN level is that the workers' hands are exposed to wood on the rip saw machine with an RPN value of 140. The proposed improvement is that machine operators must use PPE when doing work, provide a grace period when moving raw materials to the rip saw machine in order to provide space for workers, routine inspections, and always moving materials after processing on the rip saw machine as well as giving a danger sign in the production process area, improving standard operational procedures and periodic supervision in accordance with PPE procedures.