Comprehensive Hazard Analysis and Risk Management Strategies in Forging Operations: A Systematic Evaluation of Workplace Safety and Operational Risks

Abstract

Forging industries are critical suppliers to automotive, aerospace, construction, and manufacturing sectors, operating in high-risk environments with heavy machinery, extreme temperatures, and hazardous materials. This study employs a comprehensive Hazard Identification and Risk Assessment (HIRA) methodology to systematically evaluate risks in forging operations. The research identifies and categorizes multiple risk domains, including mechanical, thermal, chemical, and ergonomic hazards. By applying rigorous assessment techniques, the study quantifies risks based on severity, probability, and exposure levels. It proposes a multilayered risk mitigation strategy encompassing engineering controls, administrative interventions, and enhanced personal protective equipment (PPE). The findings emphasize the importance of proactive safety management, providing a structured framework for continuous risk monitoring and effective workplace hazard minimization in forging environments.