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International Journal of Engineering & Technology, 7 (3.24) (2018) 1-7 International Journal of Engineering & Technology Website: www.sciencepubco.com/index.php/IJET Research paper Analysis of the Potential Hazard Identification and Risk Assessment (HIRA) and Hazard Operability Study (HAZOP): Case Study Bambang Suhardi 1 *, Pringgo Widyo Laksono 2 , Andhika Ayu V.E 3 ., Jafri Mohd.Rohani 4 , Tan Shy Ching 5 1,2,3 Department of Industrial Engineering, Faculty of Engineering, Universitas Sebelas Maret, Surakarta, Central Java, Indonesia 4,5 Faculty of Mechanical Engneering, Universiti Teknologi Malaysia, 81310, Skudai, Johor, Malaysia *Corresponding author E-mail:bambangsuhardi@staff.uns.ac.id Abstract This study aims to investigate the potential hazards and accidents that might occur at batik printing PT. Batik Merak Manis and recom- mends practical solutions to enhance safety and health at the workplace. This research adopts Hazard Identification Risk Assessment (HIRA) and Hazard and Operability Studies (HAZOP) to perform risk identification and assessment in the workplace. There are 17 find- ings of potential hazards in the production areas of batik printing which can be categorized into five types of hazards including: workers attitude, work posture, work procedure, workstation, and physical work environment. Of the risk assessment, the obtained value of 34% in the category of extreme hazard, 24% hazard in the high and medium category respectively, and 18% lower hazard category. Proposed improvements are made based HAZOP analysis worksheet. The proposed practical solutions include improvements in work attitude, work posture, and physical work environment. Keywords: HAZOP, HIRA, Risk Assessment, Source of Hazard. 1. Introduction Hazard is the cause or circumstances that have the potential to cause injury or illness to humans, property damage, and pollutions of the environment or a combination of all of them [26]. The term of hazard shows as an incident that could cause injury [8]. Hazards are the potential causes that endanger human health, property or the environment, which may cause accidents under certain [23]. All work activities contain the potential danger or hazard [24]. Potential hazards in the process of making batik are caused by working in the unsafe conditions, such as working posture is not ergonomic, contacting with chemicals in the dyeing process, ex- posing to the heat coming from the furnace during the process coloration [1]. Agusti [2] stated that the space and work equipment used during the process of batik in the textile industry, in general, are still cat- egorized as less ergonomic. This condition is due to the working facilities do not consider the needs and employability of workers. For instances, seating, gawangan and physical working environ- ments such as poor lighting levels, high temperature and environ- mental conditions that are considered as less clean. Besides, the institution of Clean Batik Initiative Centre [10, 11, 12, 6] has highlightedthe use of chemicals in the batik industry. The used chemical in batik industries comprised of caustic soda (NaOH), hydrochloric acid (HCL), sodium nitrite (NaNO 2 ), hydrogen per- oxide (H 2 O 2 ), sodium dithionite (Na 2 S 2 O 4 ), sodium carbonate (Na 2 CO 3 ), sodium silicate (Na 2 SiO 3 ) and naphtol dye. These chemical materials are categorized into hazard and toxic substanc- es. A correct working procedure is necessary to be considered in handling those chemical materials [31]. Such hazardous and toxic materials in case of direct contact with the skin can cause a burnng sensation on the skin, itching and if there’s a direct contact in the long term will lead to disease and chronic effects. Labour is one of the most important assets in the batik industry. Emploers must provide assurance of safety and health for workers. The Occupational Safety and Health department is attempted to ensure the integrity and physical and spiritual perfection of man and employment in particular together with the results of his work in order towards a just society, and prosperous [33, 9]. Work safe- ty is a process to plan and control the situation of the potential workplace accidents through the preparation of standard. Claimed that the awareness of employers to provide an assurance of safety and health for workers in Indonesia is still at the low level [5, 25]. An enterprise can be classified as a small or medium enterprise (SME) if it has a number employee from 5 to 99 people [29]. PT. Batik Merak Manis which is categorized as SME is one of the batik’s producer in Solo. Production of batik printing in this com- pany is based on the Indonesian National Standard (SNI) of batik. This company produces some products such as batik printing (ma- chine printed batik), batik tulis (written batik), and batik cap (manually printed batik) [7]. Batik printing is more contributing to economic growth of the textile industry compared to batik tulis and batik cap. The production of machine printed batik fabric reached 4.000 pieces per day. The production quantities of batik cap and batik tulis, each for 800 pieces and 20 pieces per day. This study focused on batik printing workstation as its high production amount per day compared to the other products. The production process of batik cloth printing as shown in Figure 1: a) preparation of raw materials such as mori cloth, b) grounding (the basic of dyeing process), c) preparation of printing, d) printing (printing