Enhancing Occupational Safety through Risk-Based Assessment: A Comparative Study of HAZOP and FMEA Methods in Metalworking SME

Occupational safety in small and medium-sized enterprises is often undermined by the absence of systematic hazard assessments.This study explores the integration of HAZOP and FMEA to improve risk identification and prioritization in a metalworking SME.A case study was conducted at UD Jaya Mandiri Lestari, a conventional lathe workshop in Medan, Indonesia.Data were collected through structured interviews, direct observation, and worker questionnaires.HAZOP was used to identify deviations in routine operations, while FMEA assigned risk priority numbers based on severity, occurrence, and detection.The combined approach revealed critical hazards such as unguarded rotating machinery, lack of personal protective equipment, and poor ventilation.The highest risk scores were associated with electrical faults and human error.Results show that using HAZOP and FMEA together offers a more effective framework for managing workplace risks than either method alone.This hybrid strategy is especially valuable for small enterprises with limited resources.The study highlights the importance of using both qualitative and quantitative tools to inform safety actions and reduce occupational risks.