Analysis of the Thinner Release Accident in the Painting Unit of Automobile Manufacture Using the Bow-Tie Method

Document Type : SEMIT 2024

Authors

1 University of Science and Culture

2 Faculty of Engineering, University of Science and Culture, Tehran, Iran.

Abstract

Paint spraying systems in the automotive industry demand strict maintenance practices to ensure operational safety and efficiency. This study investigates a significant thinner leak incident at Paint Shop 1 of an automobile manufacturing facility, where a hose detached due to inadequate maintenance and insufficient replacement provisions. The Bow-Tie method was employed to systematically analyze the incident, mapping out threats, consequences, and barriers to reveal critical deficiencies in the organization’s safety controls and leadership engagement. The analysis uncovered a weak safety culture and highlighted the absence of preventive mechanisms, such as proper hose management and real-time leak detection systems. The study’s main contribution lies in the application of the Bow-Tie method in the automotive manufacturing context, where its use has been limited compared to high-risk industries like petrochemicals. Key recommendations include updating hose management systems, installing secure pipe racks, and incorporating IoT-enabled leak detection and predictive maintenance technologies. The findings provide a practical framework for improving risk assessment and promoting a more resilient safety culture in similar manufacturing environments, emphasizing the importance of leadership involvement and technological upgrades in accident prevention.

Keywords

References

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Journal of Optimization and Supply Chain Management
Volume 2, Issue 1
March 2025
Pages 59-69

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