A Risk Assessment of Company XYZ’s Mull Assembly Line

Abstract

The objectives of this study were to conduct a risk assessment of Company XYZ’s mull assembly line and provide cost effective mitigation recommendations for risks that were identified as being medium to high in relation to a risk assessment tool. By referencing the ANSI/ASSP Z590.3-2021 Prevention Through Design Standard, the researcher objectively performed a risk assessment of Company XYZ’s mull assembly as well as conducted noise level monitoring throughout this production area. The identified mull assembly line injury risks involved force and posture-related ergonomic stressors, physical contact with powered industrial truck traffic as well as skin punctures from a pneumatic tool. Additional risk-based concerns included wood dust accumulations, missed monthly fire extinguisher inspections and an emergency exit sign. The mitigation approaches for ergonomic issues included rotation of employees every two hours, the utilization of tape instead of staples for decreased box opening stress, and a fixture which is designed to support the weight of pneumatic tools. The proposed risk mitigation strategy for the potential employee forklift contact involved segregating the storage, material staging, and travel paths throughout the facility. The puncture risk due to high frequency of using pneumatic tools would necessitate a need to perform annual training on such devices Risk mitigation measures for the significant wood dust accumulations, the missed fire extinguisher monthly inspections and exit sign within the mull assembly area necessitate the need to perform routine daily housekeeping, updated fire extinguisher inspection routines as well as the purchase and install of a new emergency exit sign.