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.

10.22034/ISS.2025.8225.1017

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

Al-Faradi, H., & Zubair, S. (2020). Managing risks in industrial systems: The role of safety leadership in hazardous industries. Journal of Industrial Safety Management, 15(2), 34–42. https://doi.org/10.1016/j.jsim.2020.06.012
Bagnoli, S., Yung, C., & Williams, A. (2021). Predictive maintenance and its impact on safety management in industrial systems. Safety Science, 136, 105122. https://doi.org/10.1016/j.ssci.2020.105122
Brown, D., Smith, P., & Lee, H. (2023). Industrial safety and preventative barriers in the paint industry. Journal of Process Safety, 19(1), 78-89.
Chen, H., Zio, E., & Niu, G. (2020). A review of maintenance optimization models for multi-component systems based on condition monitoring information. Reliability Engineering & System Safety, 198, 106925. https://doi.org/10.1016/j.ress.2020.106925
Cooper, M. D. (2020). Behavioral safety: A framework for success. Safety Science, 127, 104703. https://doi.org/10.1016/j.ssci.2020.104703
Duarte, C. A., Silva, P. A., & Costa, J. A. (2021). The role of secure mounting in reducing mechanical stress in industrial transfer systems. Journal of Mechanical Engineering, 22(4), 345–355. https://doi.org/10.1016/j.jmecheng.2021.01.017
Gao, Z., Yang, Y., & Wang, J. (2023). Human and organizational factors in major accident prevention: An analysis using Bow-Tie methodology. Process Safety and Environmental Protection, 172, 621–630. https://doi.org/10.1016/j.psep.2023.01.015
Garcia, M. L., & Patel, S. R. (2021). Integrating dynamic risk assessment and IoT-based tools in the Bow-Tie method. Journal of Risk Management, 34(4), 456-473. https://doi.org/10.1016/j.jrm.2021.05.012
Jones, D., & Smith, T. (2022). The evolution of Bow-Tie methods in modern industrial applications. Safety Science, 130, 104737. https://doi.org/10.1016/j.ssci.2021.104737
Khan, F. I., & Haddara, M. (2022). A framework for risk-based maintenance of process systems. Journal of Quality in Maintenance Engineering, 28(1), 134–149. https://doi.org/10.1108/JQME-09-2020-0076
Khan, F. I., Sadiq, R., & Haddara, M. (2022). Risk-based maintenance of process systems: A review. Journal of Quality in Maintenance Engineering, 23(2), 134-155.
Lee, Y., Kim, B., & Williams, D. (2023). Enhancing Bow-Tie analysis with real-time monitoring and risk communication. Journal of Hazardous Materials, 418, 127594. https://doi.org/10.1016/j.jhazmat.2021.127594
Olawoyin, R. (2020). Risk analysis and safety culture assessment in high-risk industries: A review. Safety Science, 132, 104983. https://doi.org/10.1016/j.ssci.2020.104983
Oktem, U., & Jones, D. (2020). The Bow-Tie methodology: Risk management applications. Journal of Hazardous Materials, 176(1-3), 120–131. https://doi.org/10.1016/j.jhazmat.2020.121970
Paté-Cornell, M. E., Dillon, R. L., & Guikema, S. D. (2021). On the integration of safety management and risk analysis. Risk Analysis, 41(6), 1027–1042. https://doi.org/10.1111/risa.13690
Presight. (2023). Improving industrial safety: Lessons from Bow-Tie risk analysis. Journal of Industrial Risk and Safety, 35(2), 189–204.
Rajabzadeh, A., Parsa, M., & Asgarian, S. (2021). Application of the Bow-Tie method in risk management: Case study of a petrochemical facility. Process Safety and Environmental Protection, 149, 258–267. https://doi.org/10.1016/j.psep.2021.04.002
Reddy, S., Kumar, A., & Lee, S. (2021). Enhancing industrial safety through Bow-Tie risk analysis: Applications and case studies. Journal of Hazardous Materials, 417, 126186. https://doi.org/10.1016/j.jhazmat.2021.126186
Reniers, G. L. L., Soudan, K., & Dullaert, W. (2021). The use of the Bow-Tie method in the chemical industry: A review. Journal of Loss Prevention in the Process Industries, 56, 252–262. https://doi.org/10.1016/j.jlp.2021.104380
Singh, J., Singh, R., & Singh, G. (2020). Reliability and maintainability analysis of paint spraying systems in the automobile industry. International Journal of Quality & Reliability Management, 36(6), 931–944.
Singh, M., Johnson, R., & Lee, P. (2020). Preventative risk barriers and safety culture: Evaluating incident scenarios using Bow-Tie analysis. Risk Management in Process Industries.
Viskari, E. L., Haapanen, S., & Henttonen, H. (2021). Development of real-time VOC detection systems in industrial settings. Sensors and Actuators B: Chemical, 339, 129858. https://doi.org/10.1016/j.snb.2021.129858
Wang, F., Zhang, H., & Liu, X. (2021). Chemical transfer system failure in petrochemical industries: A case study of a hose leak incident. Journal of Process Safety and Environmental Protection, 147, 91–101. https://doi.org/10.1016/j.psep.2021.01.012
Yang, S., Gu, L., & Kim, J. (2023). Optimization of hose management systems in fluid transfer industries: A comprehensive study. International Journal of Fluid Mechanics, 58(1), 102–113. https://doi.org/10.1016/j.ijfluid.2023.01.004
Zhou, Y., Sun, Y., & Lin, M. (2022). Risk assessment methods in petrochemical industries: Application of the Bow-Tie approach in hazardous material management. Safety Science, 146, 105567. https://doi.org/10.1016/j.ssci.2021.105567
Journal of Optimization and Supply Chain Management
Volume 1, Issue 3
March 2025
Pages 205-215

Files

Share

How to cite

Statistics