Metal sektöründe soğuk şekillendirme prosesinde 3T risk analizi metodu uygulamaları
3T risk assessment method and applications at cold forming in metal industry
Yazar: SERAP KAŞ
Danışman: PROF. DR. MUSTAFA AKDAĞ
Gediz Üniversitesi / Fen Bilimleri Enstitüsü / Endüstri Mühendisliği Ana Bilim Dalı / İş Güvenliği ve Sağlığı Bilim Dalı
Derece: Yüksek Lisans, 2015
Konu: Endüstri ve Endüstri Mühendisliği = Industrial and Industrial Engineering

Özet:
Metal sektöründe soğuk şekillendirme prosesinde 3T risk analizi metodu uygulamaları. Gediz Üniversitesi Fen Bilimleri Enstitüsü İş Sağlığı ve Güvenliği Programı Yüksek Lisans Tezi, İzmir, 2015. 
Bu çalışmada 3T risk değerlendirmesi yöntemi kullanılarak, sac ve metal kalıp tasarımı, sac ve metal kalıp imalatı, metal sac işleme ve pres ile soğuk şekillendirme faaliyetleri olan orta ölçekli bir fabrikada iş sağlığı ve güvenliği tehlikelerini belirlemek amacıyla yapılan değerlendirmenin sonuçları ve faaliyet planı sunulmuştur. Ayrıca Fine-Kinney risk değerlendirme yöntemi ile tespit edilen tehlikeler tekrar analiz edilmiş ve frekansın riskin derecelendirmesini hesaplamada ortaya çıkaracağı farklılıklar değerlendirilmiştir.
Öncelikle risk değerlendirmenin mevzuatımızdaki yeri ve önemi irdelenmiş, İş Kanunundan başlayarak risk değerlendirmesi anlamında işverenin yükümlülükleri açıklanmıştır. Ardında risk değerlendirmesinin yer aldığı tüm mevzuat başlıkları listelenmiş,  ilgili yönetmeliklerle konunun öneminin altını kalın olarak çizilmiştir. 
Risk değerlendirme yaparken genel olarak izlenmesi gereken adımlar açıklanmış, kullanıla bilinecek belli başlı risk değerlendirme yöntemleri listelenmiş ve 3T risk değerlendirme metodolojisi detaylı bir şekilde aktarılmıştır.
3T risk değerlendirme metodunun tüm modülleri tek tek ele alınarak açıklanmış ve her bir modülün ayrı ayrı güvenlik modül endeksi hesaplanmıştır. Daha sonra tüm işletmenin genel güvenlik endeksi hesaplanmıştır. Ardından Fine-Kinney risk değerlendirme metodolojisi ile tehlike ve riskler tekrar değerlendirilerek, frekansın riskin öneminin algılanmasında ve faaliyet planındaki sırasının belirlenmesindeki rolü irdelenmiştir.
Bu değerlendirme sonucu tespit edilen tehlikelere yönelik iyileştirme faaliyetleri, bu faaliyetlerin yürütüm sorumluları ve risk puanına göre belirlenmiş terminlendirme ile bir faaliyet planı hazırlanmıştır. Yapılan risk değerlendirmesinde uygun bulunmayan ve risk değerlendirme matrisine göre risk puanı 4 ve 5 olan, önemli ve vahim durumdaki riskler için kabul edilemez düzeyde oldukları tespit edilmiştir. Bu risklerin belirlenen öncelikli riskler olarak derhal iyileştirici önlemler alınması gerekliliği ve risklerin kabul edilebilir seviyelere indirgenmesi gerekliliği ortaya konmuştur.
Ayrıca risk değerlendirmesinde bir ekip oluşturulması ve çalışanların da bu ekibin faaliyetleri sırasında aktif katılımının sağlanması ile birlikte, çalışanların risk değerlendirmenin temel kurallarını öğrenmelerinin önemi vurgulanmıştır.

Abstract:
3T risk assessment method and applications at cold forming in metal industry. Gediz University Institute of Sicence and Technology, Master Thesis in Occupational Health and Safety, İzmir, 2015. 
Various administrative steps are available in occupational health and safety management. The greatest responsibility for the management of occupational health and safety management is to determine the policies and goals. Risk assessment is located in the most important point in these steps. Because while the right corrective and preventive measures are taken against certain risks that may occur in the workplace at the point of danger, it is critical to verify the risks correctly. Risk assessment done with a team, ensuring the involvement of employees, employees will tend to increase the awareness of safety and will be encouraged to contribute. Risk is intertwined with constant and easily understandable by people who work in these environments can be applied by anyone, it will increase awareness and responsibility by performing the risk assessment targeted.
In this thesis, a medium sized metal mold designing, metal mold manufacturing, sheet metal processing and cold forming factory studied and an action plan to determine the occupational health and safety hazards presented. Fine-Kinney risk assessment methodology was again detected by analyzing hazards and frequency differences that arise in the calculation of the risk ratings are assessed.
In this study, first of all the importance of risk assessment in our legislation is discussed. Starting from the business law, the employer's liability in risk assessment is explained. After that, the headlines in our legislation where the risk assessment is important is listed and the importance of the issue with the relevant regulations have been highlighted.
Next step is by considering the concept of risk and risk assessment, the steps that must be followed when analyzing overall.are described.As a general rule, these 5 steps are described as;

Step 1. Identification of Hazard
Step 2. Analysis of Risk
Step 3. Deciding to control measures
Step 4. Completion of control measures
Step 5. Monitoring and repetition


These steps are explained individually.
Again in general risk assessment methods are divided into two main groups.
1.	Qualitative methods
2.	Quantitative methods

The basic formula of quantitative methods is given as shown below.

Risk = Probability x Intensity

The main risk assessment methods most commonly used in our country are listed as;

•	Preliminary hazard analysis (PHA)
•	Job safety analysis (JSA)
•	What if..?
•	The primary risk analysis using the checklist (PRA Using checklists)
•	Risk assessment decision matrix (L matrix, X matrix)
•	Hazard and operability study (HAZOP)
•	Fault tree analysis (FTA)
•	Failure mode and effects analysis (FMEA)
•	Event tree analysis (ETA)
•	Fine - Kinney method
•	Hazard analysis and critical control points (HACCP)
•	3T risk assessment

The 3T risk assesment methodology has been transferred in a detailed way. Fundamental properties of the method listed as;

1. Modular structure
- 5 basic module (almost all compulsory)
- 10 special module (available when necessary)

2. A4 principle
- Each module in the form of an A4

3. Each module 5 to 10 easy questions
- The existence of basic hazard
- True / false answers

4. Pages with additional information received
- Hazards and control requirements

5. The new practical risk matrix for the evaluation of hazards
- Potential intensity
- Current control level (instead of the possibility of)

All modules of 3T risk assessment methods are described one by one.
Basic modules;
A. Hazards that can cause accidents
B. Physical hazards in the workplace
C. Chemical and biological hazards in the workplace 
D. The stress factors of musculoskeletal system
E. Structures that psychosocial stressors at work

Special modules;
F. Domestic shipping and handling
G. Driving in general traffic
H. Machinery and hand tools
I.  Fire safety
J. Environmental issues
K. Workplace safety and behavior culture
L. Commercial buildings and add-ons
M. Installation and maintenance work
N. Occupational health services
O. Special nature of the assessed work

Risk assessment matrix at this point are evaluated. Intensity scale of the matrix is as follows:
1. Light severe
  • slight injury or illness, inability to work up to 3 days
2. Moderate to severe
  • long-term injury or illness; As simple injuries or fractures
  • inability to work up to 30 days
3. Extremely severe
• permanent injury / illness or death
• finger cut, second / third degree burns, skull fractures, cancer, asthma
Control scale is as follows:
1. Measures and controls are adequate, has no problem to appear. More specifically:
a) machines, instruments and structures are consistent with laws and standards,
b) The work is designed to be healthy and safe, and has been organized,
c) Employees trained and really correct (safe) use working practices.
2. The amount of improvement is needed, problems have emerged.
3. There is a need for serious improvement, problems are frequently appears.
An analysis performed for the company are examined in terms of business and safety module index is still calculated separately for each module. Then it calculated overall safety index for all operations.
The action plan fort he evaluation of the hazards identified for improvement activities, responsible people for these activities determined according to the risk score is prepared and approval has been submitted to the employer. Based on the risk assesment matrix, the significant and unacceptable risk for serious cases were scored as 4 or 5. These are primarily identified risks and necessary to take immediate remedial measures. Then Fine-Kinney risk assessment methodology with the re-evaluation of hazards and risks, the perception of the importance of risk in order to determine the frequency and role of the action plan was discussed.
In addition, to establish a team of risk assessment and the active participation of the employees to this team, employees learn the basic rules of risk assessment has been made. Another benefit of this study, the employees increased the health and safety awareness, self-control mechanism works has been made.