Hazardous Waste Risk Analysis in Heavy Equipment Maintenance

Abstract

The increasing frequency of heavy equipment maintenance activities has led to a significant rise in hazardous waste generation, which may pose operational, environmental, and occupational health and safety (OHS) risks if not properly managed. This study aims to identify failure modes, prioritize risks using Failure Mode, Effects, and Criticality Analysis (FMECA), determine root causes through Root Cause Analysis (RCA), and develop improvement recommendations for hazardous waste management in heavy equipment maintenance activities at PT XYZ. A case study approach was employed, with data collected through field observations, interviews, documentation, and expert judgment involving four experts. Risk assessment was conducted using Severity (S), Occurrence (O), and Detection (D) scores to calculate the Risk Priority Number (RPN). Normalized RPN (NRPN) values were classified as high risk (NRPN > 75%), moderate risk (50% < NRPN ≤ 75%), and low risk (NRPN ≤ 50%). The results identified 15 failure modes, comprising four high-risk, nine moderate-risk, and two low-risk failure modes. FM-08, involving contamination of the drainage system by used oil and dirt, had the highest RPN of 324 (NRPN = 100%). The four high-risk failure modes were further analyzed using RCA, which identified human factors, work methods, and facilities as the predominant root cause categories, with material and environmental factors also contributing to several failure modes. Improvement recommendations were subsequently developed using the 5W+1H approach. The integration of FMECA and RCA provides a systematic framework for prioritizing risks, identifying root causes, and formulating targeted improvements in hazardous waste management during heavy equipment maintenance activities.