SIMOP
SIMOP
Article
Hazard Identification and Risk Assessment During
Simultaneous Operations in Industrial Plant Maintenance Based
on Job Safety Analysis
Sung-Jin Kwon 1 , So-Won Choi 1 and Eul-Bum Lee 1,2, *
1 Graduate Institute of Ferrous and Eco Materials Technology, Pohang University of Science and
Technology (POSTECH), Pohang 37673, Republic of Korea; [email protected] (S.-J.K.);
[email protected] (S.-W.C.)
2 Department of Industrial and Management Engineering, Pohang University of Science and
Technology (POSTECH), Pohang 37673, Republic of Korea
* Correspondence: [email protected]; Tel.: +82-(54)-279-0136
Abstract: The risk of accidents during simultaneous operations (SIMOPS) in plant maintenance has
been increasing. However, research on methods to prevent such accidents has been limited. This
study aims to develop a novel framework, hazard identification and risk assessment of simultaneous
operations (HIRAS), for identifying and evaluating potential hazards during concurrent tasks. The
framework developed herein is expected to be an effective safety management tool that can help
prevent accidents during these operations. To this end, the job location and hazard information
in job safety analysis (JSA) were standardized into four attributes. The standardized information
was then synchronized spatially and temporally to develop a HIRAS model that identifies and
assesses the impact of hazards between operations. The model was tested using 40 JSA documents
corresponding to maintenance operations at Company P, a South Korean steel-making company.
The model was tested in two scenarios: one with planned operations and the other with unplanned
operations in addition to planned operations. The performance evaluation results of the first scenario
showed an F1-score of 98.33%. In this case, a recall of 97.52% means that the model identified
97.52% of the hazard-inducing factors. The second scenario was compared with the results of a
review by six subject matter experts (SMEs). The comparison of the results identified by the SMEs
Citation: Kwon, S.-J.; Choi, S.-W.; Lee, and the model showed an accuracy of 89.3%. This study demonstrates the potential of JSA, which
E.-B. Hazard Identification and Risk
incorporates the domain knowledge of workers and can be used not only for individual tasks but
Assessment During Simultaneous
also as a safety management tool for surrounding operations. Furthermore, by improving the plant
Operations in Industrial Plant
maintenance work environment, it is expected to prevent accidents, protect workers’ lives and health,
Maintenance Based on Job Safety
Analysis. Sustainability 2024, 16, 9277.
and contribute to the long-term sustainable management of companies.
https://doi.org/10.3390/su16219277
Keywords: simultaneous operations (SIMOPS); job safety analysis (JSA); hazard identification and
Academic Editor: Giada La Scalia
risk assessment of simultaneous operations (HIRAS); plant maintenance; Zettelkasten method; hazard
Received: 23 September 2024 identification; risk assessment; GPT 3.5
Revised: 21 October 2024
Accepted: 22 October 2024
Published: 25 October 2024
1. Introduction
1.1. Background of Study
traffic flow on an existing one, welding pipes in a petrochemical plant while handling
flammable materials in adjacent units, and performing maintenance on a nuclear power
plant while continuing to generate electricity.
SIMOPS are especially common in complex industries like oil and gas [3]. In offshore
drilling, a typical SIMOPS scenario could involve drilling activities happening on a platform
while maintenance crews are performing repairs on the rig and another team is conducting
crane operations to transfer equipment.
Investigations into the cause of major accidents in the oil and gas sector have revealed
that SIMOPS are a major factor in such accidents [4]. SIMOPS are situations where two or
more tasks are carried out in close temporal and spatial proximity. SIMOPS activities, if
uncoordinated, could pose risks to safety, environment, or equipment. Therefore, careful
safety management during SIMOPS is necessary.
The 1987 Marathon Oil refinery accident and the 1988 Piper Alpha offshore platform
accident highlight the need for caution during SIMOPS. These incidents led to efforts in
the oil and gas industry to prevent accidents during SIMOPS [5]. The International Marine
Contractors Association (IMCA) developed and issued guidelines for preventing SIMOPS
accidents [6]. SIMOPS risks are not limited to specific sectors, such as the oil and gas
industry. In 2020, an accident occurred during maintenance operations at the Evergreen
Packaging plant, prompting the U.S. Chemical Safety and Hazard Investigation Board
to recommend the development and implementation of an accident prevention program
during SIMOPS [7].
Japan’s Industrial Safety and Health Act provides a comprehensive framework for
protecting workers from workplace hazards. While the Act does not explicitly mention
SIMOPS, its general principles and requirements apply to such operations [8]. Japan’s
Ministry of Health, Labor and Welfare (MHLW) is the government agency responsible for
enforcing the Industrial Safety and Health Act. It has taken several measures to address the
risks associated with SIMOPS work. The concept of on-site safety and health management
system, or total management, was specifically implemented for the construction and
shipbuilding sectors.
While there is not a specific term SIMOPS widely used in Chinese regulations, the
Chinese government has implemented a comprehensive framework of safety regulations
and standards to prevent industrial accidents [9], particularly in high-risk industries such
as oil, gas, and construction. State-owned enterprises like the China National Petroleum
Corporation (CNPC) have developed detailed Health, Safety, and Environmental (HSE)
management systems [10]. As the primary regulatory body for workplace safety in China,
State Administration of Work Safety (SAWS) has issued numerous regulations and stan-
dards aimed at preventing industrial accidents [11].
Germany’s Occupational Safety and Health Act (ArbSchG) and the German Social
Accident Insurance (DGUV)’s accident prevention regulations set important guidelines for
managing workplace safety, including SIMOPS [12,13]. Both laws focus on ensuring that
employers and workers take necessary precautions to prevent accidents, particularly in
high-risk environments.
In South Korea, public concern about safety accidents due to SIMOPS has been in-
creasing. Accidents such as the 2014 Goyang Terminal accident, the 2017 Taean Power
Plant accident, and the 2019 Han Express accident indicate that safety during SIMOPS is
not guaranteed [14]. In particular, a report by the Korea Occupational Safety and Health
Agency (KOSHA) indicated that the number of SIMOPS accidents in South Korea has
been increasing over the past seven years. Therefore, efforts to prevent SIMOPS accidents
are necessary. Figure 1 shows the number of occupational fatalities and fatalities due to
SIMOPS in South Korea [14,15].
Sustainability 2024, 16, x FOR PEER REVIEW 3 of 29
Sustainability 2024, 16, 9277 3 of 28
Figure 1. Occupational fatalities and the proportion of occupational fatalities due to SIMOPS during
Figure 1. Occupational fatalities and the proportion of occupational fatalities due to SIMOPS during
2016–2022.
2016–2022.
The South
The South Korean
Korean government
governmenthas hastaken
takenthethe
following
followingsteps to prevent
steps SIMOPS
to prevent SIMOPSac-
cidents [16]:
accidents [16]:
•• TheThe2017
2017Amendment
Amendment to to the
the Occupational
Occupational Safety
Safety and
and Health
HealthAct:Act:Article
Article68
68mandates
mandates
appointing a health and safety coordinator to prevent industrial accidentsdue
appointing a health and safety coordinator to prevent industrial accidents duetoto
work interference when two or more construction projects are carried out at thesame
work interference when two or more construction projects are carried out at the same
location.
location.
•• TheThe2019
2019Amendment
Amendment to to the
the Occupational
Occupational Safety
Safety and
and Health
Health Act:
Act:Article
Article63
63expands
expands
the obligation of the contractor with respect to safety and health
the obligation of the contractor with respect to safety and health measures from measures from 22
hazardous locations to the entire workplace.
22 hazardous locations to the entire workplace.
•• TheThe2021
2021Amendment
Amendment to to the
the Occupational
Occupational Safety
Safety and
and Health
HealthAct:Act:Article
Article64
64mandates
mandates
that the timing, content, and safety and health measures of the operations
that the timing, content, and safety and health measures of the operations be confirmed be con-
firmed for operations carried out at the same location. The Presidential
for operations carried out at the same location. The Presidential Decree prescribes Decree pre-
scribes adjusting
adjusting theand
the timing timing and operation
operation in the
in the case of acase
fireof
oraexplosion
fire or explosion
risk duerisk due
to work
to work interference.
interference.
Companies are
Companies are also
also making
making efforts
efforts toto prevent
prevent SIMOPS
SIMOPS accidents.
accidents.The Theleading
leadingSouth
South
Korean steel
Korean steel maker,
maker, Company
CompanyP,P,has hasimplemented
implemented thethe
following
followingprocesses
processesto prevent SI-
to prevent
MOPS accidents during maintenance
SIMOPS accidents during maintenance work: work:
•• System
System aspects:
aspects: The
TheCompany
Company provides
providesa SIMOPS
a SIMOPS prediction list and
prediction listjob
and safety anal-
job safety
ysis (JSA) by linking an integrated safety and health platform with the
analysis (JSA) by linking an integrated safety and health platform with the enterpriseenterprise re-
source planning (ERP) system for work planning. The SIMOPS prediction
resource planning (ERP) system for work planning. The SIMOPS prediction list is list is gen-
erated based
generated on work
based on workdates andand
dates equipment classification
equipment systems.
classification systems.
•
• Work planning aspects: Managers from the work planningdepartment,
Work planning aspects: Managers from the work planning department,safety safetyman-
man-
agers, and work managers review the SIMOPS predictions in a D-1 meetingbefore
agers, and work managers review the SIMOPS predictions in a D-1 meeting before
the work
the work begins.
begins. Based
Based onon the
the review
review results,
results,they
theyestablish
establishmeasures
measuressuch suchasaspro-
pro-
hibitingconcurrent
hibiting concurrent vertical
vertical work,
work, adjusting
adjusting work
work execution
executiontimes,
times,andandimplementing
implementing
additionalsafety
additional safety measures.
measures.
• Work permit aspects:
• Work permit aspects: The The work
work permit
permit issuer
issuer reviews
reviews whether
whetherthe thework
workisismixed
mixed
with other teams for upstream, downstream, or interlocking equipment.IfIfSIMOPS
with other teams for upstream, downstream, or interlocking equipment. SIMOPS
are confirmed,
are confirmed, the
the work
work permit
permit issuer
issuer facilitates
facilitates aa toolbox
toolbox meeting
meeting (TBM)
(TBM)during
during
which work supervisors inspect the equipment on-site, identify potential
which work supervisors inspect the equipment on-site, identify potential hazards, hazards,
and
and establish
establish countermeasures
countermeasures [17]. [17].
• Work execution aspects: Workers are invited to a TBM with the operations and equip-
ment supervisors for individual tasks as well as a TBM with the related equipment
task supervisors.
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• 9277
Sustainability 2024, 16, Workexecution aspects: Workers are invited to a TBM with the operations and 4 of 28
equipment supervisors for individual tasks as well as a TBM with the related equip-
ment task supervisors.
Although these processesthese
Although are effective
processesinare preventing
effective inSIMOPS accidents,
preventing SIMOPS theyaccidents,
have they have
drawbacks. The time required
drawbacks. The for
timeindividual
required fortaskindividual
TBMs is not taskuniform,
TBMs isleading to delays
not uniform, leading to delays
when additional TBMs
when are required.
additional TBMsThe aretime required
required. Thefor additional
time required TBMs increasesTBMs
for additional with increases with
an increase in an
theincrease
numberinofthe SIMOPS,
numberthereby
of SIMOPS,potentially
therebyshortening
potentially the time available
shortening the time available for
for maintenance work. Furthermore,
maintenance prioritizingprioritizing
work. Furthermore, multiple targets
multipleduring additional
targets TBMs
during additional TBMs can
can be challenging.
be challenging.
The risks
The risks associated withassociated
SIMOPS in with SIMOPS
plant in plant
maintenance aremaintenance are expected
expected to increase in to increase
in the future.
the future. As companies As companies
constantly strive toconstantly strive and
improve quality to improve quality
productivity and
[18], productivity [18],
many
many production
production activities in industrial activities
sites areinmechanized
industrial sites
and are mechanized
automated, andto
leading automated,
an in- leading to
an in
evitable increase inevitable
maintenanceincrease
work inand
maintenance
personnelwork andMaintenance
[19–22]. personnel [19–22].
work inMaintenance
plants work in
plants is compared
is a high-risk activity a high-riskto activity
other compared
tasks. From to other
2000 tasks. From
to 2011, 2000ofto184
80 out 2011, 80 out of 184 major
major
accidents in theaccidents in the process
process industry industry
in the U.S. in thewere
and Europe U.S. related
and Europe were related
to maintenance work to maintenance
work [23]. Therefore, the increase in maintenance SIMOPS
[23]. Therefore, the increase in maintenance SIMOPS in plants corresponds to a higher in plants corresponds to a higher
probability
probability of workers beingof workers
exposedbeing exposed
to accident to accident risks.
risks.
A process for
A process for identifying andidentifying and assessing
assessing work work hazards
hazards before startingbefore
work is starting
crucialwork is crucial
for preventingfor preventing
accidents [24]. accidents
JSA can help [24].identify
JSA canand helpassess
identify
workand assess [25]
hazards workand hazards
has [25] and has
been long used in various industries such as oil, construction, automation, mining, and mining, and
been long used in various industries such as oil, construction, automation,
shipbuilding
shipbuilding [26]. In JSA, the[26].
task In JSA, theinto
is divided tasksequential
is divided into the
steps, sequential
hazardssteps,
at eachthestephazards at each
step are identified and assessed, and hazard risk mitigation
are identified and assessed, and hazard risk mitigation measures are established [27]. Fig- measures are established [27].
Figure 2 depicts the JSA process currently
ure 2 depicts the JSA process currently implemented in Korea. implemented in Korea.
Figure3.
Figure 3. Overall
Overall research
research process.
process.
2.2. Literature
Literature Review
This
This section
section categorizes previous studies
categorizes the previous studies into
intoaa total
totalof
offour
fourgroups:
groups:one
onegroup
group
focusing
focusing on on hazard
hazard identification and assessment
assessment methodologies,
methodologies,and andthree
threecategories
categoriesfor
for
prior
priorresearch
research related
related to
to JSA.
JSA.
2.1.
2.1. Methodologies
Methodologies for for Hazard Identification and
Hazard Identification and Risk
Risk Assessment
Assessmentin inthe
theConstruction
ConstructionSectorSector
Hazard identification and risk assessment (HIRA) is a collective term
Hazard identification and risk assessment (HIRA) is a collective term that encom- that encompasses
all activities
passes involvedinvolved
all activities in identifying hazards hazards
in identifying and evaluating risk at facilities.
and evaluating The public
risk at facilities. Theor
the environment
public are consistently
or the environment controlledcontrolled
are consistently within each organization’s
within risk tolerance
each organization’s risk level.
tol-
Tools for simple hazard identification or qualitative risk analysis include
erance level. Tools for simple hazard identification or qualitative risk analysis include checklists, what-if
analysis,
checklists, hazard
what-ifand operability
analysis, hazardstudies (HAZOP), studies
and operability and failure modesand
(HAZOP), andfailure
effect analysis
modes
(FMEA) [33].
and effect analysis (FMEA) [33].
Checklists
Checklists offerofferaastraightforward
straightforwardand andtime-efficient
time-efficientapproach
approachtoto hazard
hazard identification,
identifica-
making them suitable for routine safety inspections [33]. What-if
tion, making them suitable for routine safety inspections [33]. What-if analysis, analysis, on the onother
the
hand, encourages
other hand, creative
encourages thinking
creative by posing
thinking hypothetical
by posing scenarios
hypothetical suchsuch
scenarios as “What
as “Whatif...?”
However, its effectiveness
if...?” However, hinges
its effectiveness on theonanalyst’s
hinges experience
the analyst’s and and
experience knowledge,
knowledge, andandit mayit
lack a systematic framework [33]. FMEA and HAZOP are more rigorous
may lack a systematic framework [33]. FMEA and HAZOP are more rigorous methodol- methodologies that
are
ogiesemployed when a detailed
that are employed when aanalysis
detailedof systemoforsystem
analysis process orsafety
processis safety
imperative [33]. JSA
is imperative
is[33].
particularly valuable when objective data are required to assess and
JSA is particularly valuable when objective data are required to assess and mitigate mitigate risks [34].
Moreover, the International Organization for Standardization (ISO) 45001
risks [34]. Moreover, the International Organization for Standardization (ISO) 45001 pro- provides a com-
prehensive framework forframework
vides a comprehensive establishing and
for maintaining
establishing an maintaining
and occupational an health and safety
occupational
management system within an organization [35]. Table 1 presents a detailed comparison of
these methods, highlighting their key characteristics, strengths, and weaknesses.
Sustainability 2024, 16, 9277 7 of 28
Table 1. Comparing hazard identification and risk assessment methods in construction sector.
for integrating the old and new perspectives on safety instead of replacing the old perspec-
tive [1]. Zheng et al. developed a visual cognitive model to improve hazard identification
at construction sites, analyzing eye-tracking data from experts and novices in 16 simulated
field scenes [43]. The findings of this study provide insights into potential improvements
for safety training and management. Hong and Cho proposed a location tracking system
that leverages personal ID recognition, QR code scanning, and computer vision algorithms
to enhance preemptive risk recognition and real-time safety monitoring in various work
environments [44].
The connection
The connection points
points between
between the
the JSAs
JSAs were
were chosen
chosen by
by matching
matching the
the SIMOPS
SIMOPS com-
com-
ponents and inter-task effects with the JSA components. The matched JSA information
ponents and inter-task effects with the JSA components. The matched JSA information was
converted into a form recognizable by the model via systematic structuring. Task locations
was converted into a form recognizable by the model via systematic structuring. Task lo-
cations were converted into coordinates, task attributes into ranges, and hazard attributes
into direction, range, and residue. The details of this conversion are provided in Section
4.2. The converted information was used in the R-JSA synchronization model to model
real-time SIMOPS situations by connecting information corresponding to the same date
and floor, and SIMOPS-related hazards were identified. These aspects are detailed in Sec-
Sustainability 2024, 16, 9277 11 of 28
were converted into coordinates, task attributes into ranges, and hazard attributes into
direction, range, and residue. The details of this conversion are provided in Section 4.2. The
converted information was used in the R-JSA synchronization model to model real-time
SIMOPS situations by connecting information corresponding to the same date and floor, and
SIMOPS-related hazards were identified. These aspects are detailed in Section 4.3. Figure 5
Sustainability 2024, 16, x FOR PEER REVIEW
shows a schematic of the SIMOPS components used to develop the R-JSA synchronization 12 of 29
model.
Figure 5. Connecting the components between SIMOPS and the R-JSA synchronization model. (S)
Figure 5. Connecting the components between SIMOPS and the R-JSA synchronization model.
*: Structured data, (U) **: unstructured data.
(S) *: Structured data, (U) **: unstructured data.
4.4.Modeling
Modeling
Section4 4provides
Section provides a comprehensive
a comprehensive description
description of development
of the the development of a HIRAS
of a HIRAS model
model designed to identify and evaluate potential hazards arising from concurrent
designed to identify and evaluate potential hazards arising from concurrent tasks. tasks.
4.1.HIRAS
4.1. HIRAS Framework
Framework
Inthis
In thisstudy,
study,thetheZettelkasten
Zettelkasten method
method was applied
applied to to develop
develop HIRAS.
HIRAS.HIRAS
HIRASwas was
usedto
used toidentify
identifyandand assess
assess possible
possible hazards during SIMOPS using JSA. JSA.
The HIRAS
The HIRAS framework
frameworkcomprises
comprisesthree
threecomponents:
components: (i) the relation-oriented
(i) the JSA (R-
relation-oriented JSA
JSA) method,
(R-JSA) method, which
whichgenerates
generatesthethe
required data
required from
data JSAJSA
from to build a database;
to build (ii) the
a database; R-
(ii) the
JSA synchronization model, which analyzes data to identify hazards
R-JSA synchronization model, which analyzes data to identify hazards during SIMOPS; during SIMOPS; and
(iii) (iii)
and SIMOPS SIMOPSrisk risk
assessment (S-RA),
assessment whichwhich
(S-RA), evaluates and prioritizes
evaluates the identified
and prioritizes risks.
the identified
The components
risks. The components are detailed below.below.
are detailed
•• R-JSA method: This methodologyaims
R-JSA method: This methodology aimstoto
standardize
standardize JSAJSAdatadata
to build an open
to build da-
an open
tabase. Coordinates
database. Coordinates areare
assigned to task
assigned locations
to task and and
locations the attributes of tasks
the attributes and haz-
of tasks and
ards are structured to standardize the data. Errors in data entry are
hazards are structured to standardize the data. Errors in data entry are prevented via prevented via
quantifiedhazard
quantified hazard classifications,
classifications, GPT
GPT validation,
validation, andand criteria
criteriafor
forhazards
hazardsthat
thatcause
cause
accidents during SIMOPS.
accidents during SIMOPS.
• R-JSA synchronization: This model uses data obtained from R-JSA to synchronize
hazard information for tasks in a spatially and temporally coordinated manner and
analyzes inter-task effects. This analysis involves the generation of synchronized
data, exploratory analysis, and hierarchical analysis, which provides a basis for iden-
tifying and assessing hazards in SIMOPS.
• S-RA: S-RA focuses on evaluating the identified hazards and determining the priority
Sustainability 2024, 16, 9277 12 of 28
• R-JSA synchronization: This model uses data obtained from R-JSA to synchronize
hazard information for tasks in a spatially and temporally coordinated manner and
analyzes inter-task effects. This analysis involves the generation of synchronized data,
exploratory analysis, and hierarchical analysis, which provides a basis for identifying
and assessing hazards in SIMOPS.
• S-RA: S-RA focuses on evaluating the identified hazards and determining the priority
Sustainability 2024, 16, x FOR PEER REVIEW 13 of 29
of actions using the information on the risk level of the source job and the SIMOPS
factor derived from expert group discussions.
The HIRAS framework integrates these components to systematically identify and
The HIRAS framework integrates these components to systematically identify and
evaluate
evaluate hazards
hazards that
that may
may occur during SIMOPS,
occur during SIMOPS, thereby
therebycontributing
contributingtotoimproving
improving
workplace safety. Figure 6 shows a conceptual map of the HIRAS framework.
workplace safety. Figure 6 shows a conceptual map of the HIRAS framework.
4.2.Data
4.2. DataStructuring
Structuring Through
Through a Relation-Oriented
Relation-Oriented JSAJSAMethod
Method
TheR-JSA
The R-JSAmethod
method standardizes
standardizes JSAJSA information
informationinto intoattribute
attributevalues,
values,and
andthus plays
thus plays
a crucial role in ensuring that the HIRAS framework is open and flexible.
a crucial role in ensuring that the HIRAS framework is open and flexible. Moreover, the Moreover, the
R-JSAmethod
R-JSA methodhelps
helps prevent
prevent the
the omission
omissionor oroverinclusion
overinclusionofofreview
reviewtargets byby
targets thethe
author.
author.
To achieve this, the improved components in the JSA methodology
To achieve this, the improved components in the JSA methodology are the location, are the location, jobjob
steps, and hazard.
steps, and hazard.
Thelocation
The locationinformation
informationwas wasclassified
classifiedinto
intofloors
floorsand
andwas
wascoordinated
coordinatedon onaacoordinate
coordi-
nate plane of the respective floor. For example, the location “2F B Facility”
plane of the respective floor. For example, the location “2F B Facility” was converted and was converted
and entered
entered as “2F-X70-Y67”
as “2F-X70-Y67” in the
in the standardized
standardized form.AA range
form. range attribute
attributewas
wasincluded
included to to
quantitativelyexpress
quantitatively express the
the scope
scope of
of each
each task.
task. For
Forexample,
example,aarange
rangeattribute
attributevalue
valueof of
fivefive
for a task step indicates the task area occupies five squares horizontally
for a task step indicates the task area occupies five squares horizontally and vertically and vertically
fromthe
from thelocation
locationin inthe
the coordinate
coordinate system.
system. Hazard
Hazardattributes
attributeswere
wereadded
addedtotosystematize
systematize
the impact on surrounding tasks, including disaster type classification, confirmation of
the impact on surrounding tasks, including disaster type classification, confirmation of
impact on surrounding tasks, and hazard attributes. Hazard attributes were divided into
impact on surrounding tasks, and hazard attributes. Hazard attributes were divided into
three categories: range, direction, and residue. Figure 7 shows a JSA form reflecting these
three categories: range, direction, and residue. Figure 7 shows a JSA form reflecting these
improvements, with the reflected parts separately marked. In Figure 7, the blue boxes de-
improvements, with the reflected parts separately marked. In Figure 7, the blue boxes
note the field engineerʹs input, while the yellow sections highlight areas where GPT assis-
tance is involved during the initial review by the first person.
Sustainability 2024, 16, 9277 13 of 28
denote
the field engineer’s input, while the yellow sections highlight areas where
Sustainability 2024, 16, x FOR PEER REVIEW 14 ofGPT
29
assistance is involved during the initial review by the first person.
Figure7.7.Example
Figure Exampleof ofaarelation-oriented
relation-orientedJSA form. 11 TR: Task range; 22S:S:selection;
JSAform. selection;33IOSO:
IOSO:impact
impactonon
surrounding operations; HR: hazard range; D: direction; R: residue; S: severity; P:P:probability;
surrounding operations; 4 4 HR: hazard range; 55 D: direction; 6
6 R: residue; 77S: severity; 8 8
probability;
9 RR: risk rating; 10 HV-: the downward direction of the horizontal and vertical; 11 H: horizontal.
9 RR: risk rating; 10 HV-: the downward direction of the horizontal and vertical; 11 H: horizontal.
Theimpact
The impact ofof hazards
hazards on on surrounding
surrounding tasks
tasks was
was evaluated
evaluated as as follows:
follows:
•• Classification of disaster types: Disaster types were classified tostructure
Classification of disaster types: Disaster types were classified to structurethethehazards
hazards
corresponding to individual tasks. As classification criteria may vary
corresponding to individual tasks. As classification criteria may vary across industries, across indus-
the 22 criteria detailed by KOHSA were used herein [58]. The classificationwas
tries, the 22 criteria detailed by KOHSA were used herein [58]. The classification was
conducted in
conducted in three
three steps.
steps. First,
First, the
the worker
worker classified
classified the
the types,
types,andandGPT
GPTwas wasused
usedtoto
assistclassification.
assist classification.The Therole,
role,classification
classificationcriteria,
criteria, and
and output
output format
format were
were specifi-
specifically
cally presented
presented in theinGPTthe prompt.
GPT prompt. The GPT
The GPT prompts
prompts were were combined
combined withwith
JSAJSA haz-
hazards
ards using text concatenation functions in Google Sheets, and the
using text concatenation functions in Google Sheets, and the GPT API was used for GPT API was used
for classification.
classification. Discrepancies
Discrepancies between
between thethetwo
tworesults
resultswere
were reviewed.
reviewed. TheTheaccuracy
accuracy
and reliability of the classification were improved by reviewing
and reliability of the classification were improved by reviewing and supplementing and supplementing
theresults
the resultsprovided
providedby byAI.
AI.Figure
Figure8 shows
8 shows a part
a part of of
thethe prompt
prompt used
used for for disaster-
disaster-type
type classification.
classification.
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x FOR PEER REVIEW 15
14 of 29
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Figure 8.
Figure 8. GPT
GPT prompt
prompt for
for disaster
disaster type
type classification.
classification.
Figure 8. GPT prompt for disaster type classification.
•• Confirmation of impact on surrounding tasks: Disaster Disaster types
types that
that could
could cause
cause acci-
acci-
• Confirmation
dents of impact
during SIMOPS on surrounding
were
were selected. Clear
selected. tasks: Disaster types
classifications thatapplied
were could cause acci-
eliminate
to eliminate
dents during
variations
variations amongSIMOPS wereand
authors
authors selected.
and ensure
ensure Clear classifications
consistent
consistent were
results.
results. Theapplied to eliminate
classification
classification criteria
criteria
variations
were based
were among
based on
on the authors and ensure
the results from a study consistent results. The classification
study conducted by the Korea Occupational criteria
Safety
were based on the results from a study conducted by the Korea Occupational Safety
and Health Research Institute, wherein 4641 accidents that occurred from 2016 to
and Health Research Institute, wherein 4641 accidents that occurred from 2016 to
2020 were analyzed according
according to to objective
objective criteria.
criteria. Among these accidents, 426 were
2020 were analyzed according to objective criteria. Among these accidents, 426 were
classified as SIMOPS accidents, and seven types of SIMOPS SIMOPS accident
accident causes
causes were
were
classified as SIMOPS accidents, and seven types of SIMOPS accident causes were
identified [14]. IfIfthe
theresults
resultsofofthe
thedisaster
disastertypetypeclassification
classification corresponded
corresponded to to
oneone
of
identified [14]. If the results of the disaster type classification corresponded to one of
of
thethe seven
seven SIMOPSaccident
SIMOPS accidentcauses,
causes,thethehazard
hazardattributes
attributes were
were reviewed. As other
the seven SIMOPS accident causes, the hazard attributes were reviewed. As other
types of accident causes do not affect surrounding tasks, the hazard attributes were
types ofaccident
accident causes do notnot affect
affectsurrounding
surroundingtasks, hazard
the hazard attributes
attributes were
not reviewed in those cases. Figure 9 shows the criteria and process for
not reviewed in those cases. Figure 9 shows the criteria and process for determining
determining
the
theimpact
impactononsurrounding
on surrounding tasks.
surrounding tasks.
tasks.
Figure 9. Criteria and process for selecting items with potential for SIMOPS accidents among disas-
Figure
Figure 9. Criteria
9. Criteriaand
ter types. andprocess
processforfor
selecting items
selecting withwith
items potential for SIMOPS
potential accidents
for SIMOPS among among
accidents disaster disas-
types.
ter types.
• Direction of the hazard: Four directions were considered: horizontal, horizontal and
•Direction of the hazard: Four directions were considered: horizontal, horizontal and
• upper,
Directionhorizontal and lower,
of the hazard: and horizontal
Four directions wereand and both upper
considered: and lower.
horizontal, The same
horizontal
upper, horizontal and lower, and horizontal both upper and lower. The sameand
hazard
upper, can occur in different directions depending on the work environment. For
hazardhorizontal
can occur and lower, and
in different horizontal
directions and both
depending on theupper
workand lower. TheFor
environment. same
example,
hazard in the
caninoccur case of
in of a fire,
different the direction
directions can vary depending on the exposure and
example, the case a fire, the directiondepending on the work
can vary depending on theenvironment.
exposure andFor
composition
example, of the space as well as the source of fire, such as gas or oil. Therefore,
composition of the space as well as the source of fire, such as gas or oil.exposure
in the case of a fire, the direction can vary depending on the Therefore,and
environmental
composition
environmental offactors
the space
factors
were
wereasconsidered
considered
based
well as thebased
source onthe
the
on of
worker’s
fire, such as
worker’s
domain knowledge.
gas orknowledge.
domain oil. Therefore,
• • Range of work
environmental and
Range of workfactors hazard: The
were The
and hazard: maximum
considered
maximum range
based that
on that
range could
the worker’sbe affected was
domainwas
could be affected considered
knowledge.
consid-
• following
Range the reviewed
ered following
of work and direction.
the reviewed
hazard: direction.
The maximum range that could be affected was consid-
• • Presence
Presence
ered ofofresidual
following residual hazard
hazard attributes:
the reviewed attributes: Therisk
direction. The riskofofa ahazard
hazardmay
may not
not bebe eliminated
eliminated
after task completion. For example, a worker might be exposed to asphyxiation or or
• after taskofcompletion.
Presence residual hazardFor example, a worker
attributes: The riskmight
of abehazard
exposed to asphyxiation
may not be eliminated
after task completion. For example, a worker might be exposed to asphyxiation or
Sustainability 2024, 16, x FOR PEER REVIEW 16 of 29
Sustainability 2024, 16, 9277 15 of 28
poisoning risks from gases accumulated during a previous task. Therefore, the resid-
poisoning risksof
ual attributes from gasesinaccumulated
hazards during
the target task were aconsidered
previous task.
[59]. Therefore, the residual
attributes of hazards in the target task were considered [59].
The worker’s domain knowledge about the impact on surrounding tasks can be
standardized by reviewing
The worker’s the attributes
domain knowledge of work
about and hazards.
the impact Moreover,
on surrounding thecan
tasks disaster type
be standard-
classification
ized by reviewingandthe
confirmation
attributes ofofwork
impact
andonhazards.
the surrounding
Moreover,tasks preventtype
the disaster omissions and
classification
overinclusion
and confirmationofofentries
impactby onthe
theauthor, while tasks
surrounding the remaining processesand
prevent omissions ensure an open of
overinclusion
framework.
entries by the author, while the remaining processes ensure an open framework.
4.3.R-JSA
4.3. R-JSASynchronization
Synchronization Model
Model for Identifying
IdentifyingHazards
HazardsininSimultaneous
SimultaneousOperations
Operations
TheR-JSA
The R-JSAsynchronization
synchronization model
model synchronizes
synchronizesinformation
informationextracted
extractedfrom JSAs
from of of
JSAs
plannedtasks
planned tasksinto
intoaacoordinate
coordinate system
system byby matching
matchingthethetemporal
temporaland
andspatial
spatialconditions
conditions
duringactual
during actualSIMOPS
SIMOPSandand analyzes
analyzes the
the inter-task
inter-taskimpacts.
impacts.This
Thisprocess
processis is
automatically
automatically
performedby
performed bythe
theJSA
JSAsynchronization
synchronization algorithm
algorithm according
accordingtotothe
thefollowing
followingthree steps:
three steps:
4.3.1.Data
4.3.1. DataGeneration
Generation
The data generationalgorithm,
The data generation algorithm,schematically
schematicallyshown
shownininFigure
Figure10,
10,isisapplied
appliedasasfollows:
fol-
lows:
⃝1 Extract date, location, and attribute information from R-JSA. Use date information to
① classify
Extract tasks
date, location,
on the sameand date
attribute
and information from R-JSA.
location information Use datetasks
to classify information to
on the same
classify
floor. tasks on the same date and location information to classify tasks on the same
⃝2
floor.
For each floor, create a task zone (TZ) using the X and Y coordinates of the job and the
② taskFor range,
each floor,
and create
create aa task zone
hazard (TZ)(HZ)
zone using the Xthe
using and Y coordinates
hazard attributes. of the job and
⃝3
the task range, and create a hazard zone (HZ)
Combine the HZs to create a single hazard layer (HL). using the hazard attributes.
③ Combine the HZs to create a single hazard layer (HL).
Thegenerated
The generateddata
datahave
have the
the following
following components:
components:
•
• TZ: date, location coordinates, and task range.
TZ: date, location coordinates, and task range.TZ
TZindicates
indicatesthe
thelocation and
location andrange of of
range
all tasks in the coordinate system.
all tasks in the coordinate system.
• • HZ:
HZ:date,
date, location
location coordinates,
coordinates,hazard
hazarddirection, hazard
direction, range,
hazard and and
range, residue. HZ in-HZ
residue.
dicates the range of identified hazards based on location coordinates.
indicates the range of identified hazards based on location coordinates. The hazardThe hazard
maybe
may beextended
extendedupwards
upwards and
and downwards
downwardsdepending
dependingononthe thedirection. If there
direction. areare
If there
residual attributes, the HZ is not reset in the system, even if the task date changes.
residual attributes, the HZ is not reset in the system, even if the task date changes.
Resetting occurs after affecting other task TZs following the date change.
Resetting occurs after affecting other task TZs following the date change.
• HL: combines all HZs on a workplace floor to create a single layer. Hazards transmit-
• HL: combines all HZs on a workplace floor to create a single layer. Hazards transmitted
ted from other floors are also included on the basis of the hazard direction. This plays
from other floors are also included on the basis of the hazard direction. This plays a
a crucial role in comprehensively identifying hazards from multiple surrounding
crucial role in comprehensively identifying hazards from multiple surrounding tasks.
tasks. Equation (1) represents the HL [60].
Equation (1) represents the HL [60].
Hazard Layer = 𝐻𝑍 (1)
n
[
Hazard Layer = HZi (1)
i =1
where the hazard layer is the set of all HZs on a particular floor, HZ denotes the hazard
coordinates, and i is the iterative variable representing each HZ.
Sustainability 2024, 16, x FOR PEER REVIEW 17 of 29
4.3.2.
4.3.2.Exploratory
ExploratoryAnalysis:
Analysis:Target–Source
Target–SourceJob JobIdentification
Identification
Target
Targetjobsjobsaffected
affectedbybysurrounding
surroundingtasks and and
tasks source jobs impacting
source surrounding
jobs impacting tasks
surrounding
are identified based on the generated data. The jobs were classified
tasks are identified based on the generated data. The jobs were classified as target and as target and source
jobs as follows:
source if the hazard-affected
jobs as follows: area (HAA)
if the hazard-affected areais(HAA)
in the TZ,
is initthe
is aTZ,
target
it isjob; if it isjob;
a target in the
if it
HZ, it is a source job. For example, in Figure 11, Job_02 is classified as a target
is in the HZ, it is a source job. For example, in Figure 11, Job_02 is classified as a target job job because
its TZ overlaps
because its TZ with the HL,
overlaps withcreating
the HL,ancreating
HAA. The overlapping
an HAA. area lies within
The overlapping the HZ
area lies of
within
Job_01, and hence, Job_01 is a source job.
the HZ of Job_01, and hence, Job_01 is a source job.
•• HAA:HAA
HAA: HAArepresents
representsthe
thearea
areawherein 𝑇𝑍i isisaffected
whereinTZ affectedbybythe
theHZ
HZofofsurrounding
surrounding
tasks as identified from the overlapping area between 𝑇𝑍 and HL. In this
tasks as identified from the overlapping area between TZi and HL. In this case, case,the
the
𝐻𝑍 of the target 𝑇𝑎𝑠𝑘 must be excluded from the HL. Equation (2) represents
HZi of the target Taski must be excluded from the HL. Equation (2) represents the the
HAA[60].
HAA [60].
Figure12.
Figure 12.Schematic
Schematicof
of hierarchical
hierarchical analysis
analysis for
for identifying
identifyingsource
sourcejob
jobhazards.
hazards.
4.4.
4.4.SIMOPS
SIMOPSRiskRisk Assessment
Assessment
Risk
Riskassessment
assessmentcomprises
comprisesaacombination
combinationofofthetheprobability
probabilityandandseverity
severityofofananaccident
acci-
expressed as a matrix.
dent expressed It allows
as a matrix. for a quantitative
It allows comparison
for a quantitative of riskofpriorities
comparison [49]. Table
risk priorities [49]. 2
Table the
shows 2 shows the risk assessment
risk assessment matrix
matrix used toused to calculate
calculate the riskthe risk[61].
score score [61].
Table2.2.Risk
Table Riskassessment
assessmentmatrix.
matrix.
Severity
Severity (S) (S)
Risk
Risk Score
Score
Minor Minor Marginal
Marginal Critical
Critical Fatality
Fatality
Very likely 10
Very likely 10 13 13 1515 16
16
Probability Probable
Probable 6 6 9 9 1212 14
14
Probability (P)
(P) Possible
Possible 3 3 5 5 88 11
11
Unlikely
Unlikely 1 1 2 2 44 77
InInthis
thisstudy,
study,the
theprevious
previousriskrisk assessmentprocedure
assessment procedure was
was modified
modified toto calculate
calculate the
the risk
risk of
level level of hazards
hazards in SIMOPS.
in SIMOPS. The Themostmost common
common method
method usedused in risk
in risk evaluation
evaluation is the
is the risk
risk priority
priority number number
(RPN),(RPN),
whichwhich
is widelyis widely
adopted adopted
due todue to its simplicity
its simplicity and conven-
and convenience [62].
ience [62]. However, while RPN is suitable for calculating the risk
However, while RPN is suitable for calculating the risk level of individual tasks,level of individual tasks,
it has
it has limitations
limitations in evaluating
in evaluating the degree
the degree of risk
of risk in simultaneous
in simultaneous operations,asasaddressed
operations, addressed in
this study. To assess how the risk in one operation affects surrounding tasksduring
in this study. To assess how the risk in one operation affects surrounding tasks during
simultaneous operations,
simultaneous operations, this
this study
study developed
developedaanew newequation
equationcalled
calledthetheSIMOPS
SIMOPS Risk
Risk
Score by incorporating factors such as work area, hazard area, and the
Score by incorporating factors such as work area, hazard area, and the number of workers number of workers
intothe
into thetraditional
traditionalRPN.
RPN.
The base risk score was extracted from the JSA of the source job, and three additional
The base risk score was extracted from the JSA of the source job, and three additional
variables derived from the R-JSA synchronization model were used. These variables,
variables derived from the R-JSA synchronization model were used. These variables, which
which indicate the SIMOPS hazard level, were derived in consultation with safety experts.
indicate the SIMOPS hazard level, were derived in consultation with safety experts. The
The risk level increases with the size of the hazard area within the work area and the
risk level increases with the size of the hazard area within the work area and the number
number of workers in the hazard area. Therefore, TZ, HAA, and the number of workers
of workers in the hazard area. Therefore, TZ, HAA, and the number of workers (N) were
(N) were selected. These were integrated into the existing risk assessment formula and
selected. These were integrated into the existing risk assessment formula and were used as
were used as variables for the SIMOPS risk assessment. The SIMPOS risk score was calcu-
variables for the SIMOPS risk assessment. The SIMPOS risk score was calculated as shown
lated as shown in Equation (3).
in Equation (3).
SIMOPSRisk
SIMOPS Score== P𝑃 ××S𝑆 ××H AA ×× 𝑁
RiskScore N, , (3)(3)
S s
TZ
where SIMOPS Risk Score represents the risk level of hazards in SIMOPS, 𝑃 is the prob-
where SIMOPS Risk Score represents the risk level of hazards in SIMOPS, PS is the probabil-
ability of the source hazard, 𝑆 is the severity of the source hazard, HAA is the hazard-
ity of the source hazard, Ss is the severity of the source hazard, HAA is the hazard-affected
affected area, TZ is the task zone, and N is the number of workers in the TZ.
area, TZ is the task zone, and N is the number of workers in the TZ.
Once the risk level of the identified hazards in SIMOPS has been calculated by the
Once the risk level of the identified hazards in SIMOPS has been calculated by the
model, priorities are established accordingly.
model, priorities are established accordingly.
Sustainability 2024, 16, 9277 18 of 28
Predictive Value
Positive Negative
Positive True Positive (TP) False Negative (FN)
Actual Value
Negative False Positive (FP) True Negative (TN)
TP + TN
Accuracy = × 100% (4)
TP + TN + FP + FN
Sustainability 2024, 16, 9277 19 of 28
• Precision is the ratio of correctly predicted positive instances to all instances predicted
as positive, as defined in Equation (5).
TP
Precision = × 100% (5)
( TP + FP)
• Recall is the ratio of correctly predicted positive instances to all actual positive in-
stances, as defined in Equation (6).
TP
Recall = × 100% (6)
( TP + FN )
• The F1-score is the harmonic mean of precision and recall, as defined in Equation (7).
The F1-score provides a comprehensive measure of the model’s performance.
( Precision × Recall )
F1 − Score = 2 × (7)
( Precision + Recall )
The predictive value is the result calculated by the R-JSA synchronization model,
whereas the actual value is derived using the rule-based system validation methodology
proposed by Knauf. The methodology proposed by Knauf compares the system-generated
results with the final results reviewed by experts in the relevant field. It evaluates the relia-
bility of the methodology by assessing how closely the results of the proposed methodology
align with expert judgment [65]. The SME team consisted of six field managers with over
ten years of safety management experience at P steel mill. Table 4 details the qualifications
of the SMEs.
R-JSAs were classified by task date for temporal synchronization and by floor coordinates
for spatial synchronization. Table 5 lists the tasks by date and floor.
Next, the tasks were placed in a coordinate system based on the coordinates of each
task, and the TZ and HZ coordinate data were generated based on the task and hazard
attributes. The HZ data were processed as follows: if there was a vertical attribute in the
HZ, coordinates were assigned to the related floor HL; if there was a residual attribute, the
HZ coordinates were assigned to the coordinate system for the second day. For example,
although Job_14 was performed on the second floor, the hazard in Step 2 had a downward
vertical attribute; therefore, the same HZ coordinates were assigned to the first-floor plane.
Once the actual work situation was modeled, it was analyzed to identify the target jobs
and source jobs as well as the hazards due to source jobs affecting target jobs. Finally, a
SIMOPS risk score was calculated for the identified results, and priorities were assigned.
The target job–source job list generated from the first scenario included 119 cases: 72
on the first day and 47 on the second day. The list was sorted based on the SIMOPS risk
score, and the priority of each item was indicated. To coordinate between jobs, information
on the safety managers of Target and source jobs and information on the hazards were
provided. For example, the hazard in Step 2 of Job_14 was found to affect JSA_24. Table 6
shows a part of the identified target job–source job list.
The results of the analysis were visualized to obtain an intuitive understanding. The
color codes and meanings of the components are detailed below. Figure 13 shows a
visualization of the results of the analysis for the first and second days of Scenario 1.
Table 7. Validation results of the JSA synchronization model for Scenario 1.
Value Performance
Accuracy Precision Recall F1-Score
TP FN FP TN
Sustainability 2024, 16, 9277 (%) (%) (%) (%) 21 of 28
118 3 1 4659 99.92 99.16 97.52 98.33
(a)
(b)
Figure 13. Results
Figureof13.
theResults
analysis
of for
the Scenario 1: (a)
analysis for first day;
Scenario (b) first
1: (a) secondday;day.
(b) second day.
• 2:The
5.3.2. Scenario Identification and Assessment
green rectangle represents TZ,of Hazards duringarea
the maximum Unplanned Work
of the task.
•
The second scenario considered in this study simulated unplanned work: aof
The yellow rectangle represents HZ, the maximum hazard area the task.
situation
• additional
wherein three The orange rectangle
tasks represents
were added to theHAA,
day 2the
taskarea
listwhere TZcompletion
after the is affected byof the HZ of
surrounding tasks.
the previous experiment was assumed. The model conducted an analysis including the
•
three additional Blue textanalyzed
R-JSAs indicatesby the
thesource of TZ and
equipment HZ. The SMEs were able to con-
manager.
• Red text indicates the source of the vertical
firm the analysis information for 37 planned tasks from Scenario attribute HZ. SMEs examined
1. The
• Purple text indicates the source of the residual
the hazards due to surrounding tasks through the JSAs of the additional attribute HZ.tasks
For example,
and the there is no
location maps of the tasks. The average number of hazards individually identified of
residual attribute hazard area on the first day due to the absence by previous
the work
SMEs was 11, which is 38.7% of the results identified by the model. When individual iden-
tification results were combined, it increased to 25, corresponding to an identification rate
of 89.3%. A significant difference was confirmed between the individual and combined
results. As the combined results converged at a higher level, the experiment was con-
cluded. Table 8 shows the results of identification obtained using the model compared to
Sustainability 2024, 16, 9277 22 of 28
information. On the second day, the residual hazard attribute for Step 5 from the
JSA_14 on the first day appears as HZ.
A confusion matrix based on the final results produced by the SMEs was used to
validate the model. In Scenario 1, a total of 4781 inter-task interactions were reviewed.
The model correctly identified 118 SIMOPS hazards (TP), three missing cases (FN), and
incorrectly identified one case (FP). The performance metrics of the model are shown in
Table 7.
Value Performance
Accuracy Precision Recall F1-Score
TP FN FP TN
(%) (%) (%) (%)
118 3 1 4659 99.92 99.16 97.52 98.33
Table 8. Identification results obtained using the model compared to SME results in Scenario 2.
Model SMEs
Target Job Source Job
JSA JSA Job Steps of
A B C D E F
Number Number Hazard
JSA_17 JSA_21 3 □ □ □ □ ✓ □
JSA_17 JSA_21 6 □ □ □ □ □ □
JSA_19 JSA_17 4 □ ✓ □ □ □ □
JSA_19 JSA_17 7 □ ✓ □ □ □ □
JSA_21 JSA_17 4 □ ✓ □ □ □ ✓
JSA_21 JSA_17 7 □ ✓ □ □ □ ✓
JSA_17 JSA_26 5 □ □ □ □ ✓ ✓
JSA_17 JSA_26 6 □ □ □ □ ✓ □
JSA_06 JSA_10 2 ✓ ✓ ✓ ✓ ✓ ✓
JSA_23 JSA_17 2 ✓ □ □ ✓ □ ✓
JSA_23 JSA_17 3 ✓ □ □ □ □ ✓
JSA_23 JSA_17 6 ✓ □ □ ✓ □ □
JSA_23 JSA_17 9 ✓ □ □ □ □ □
JSA_26 JSA_17 4 □ □ □ □ □ □
JSA_26 JSA_17 7 □ □ □ □ □ □
JSA_17 JSA_21 4 □ ✓ □ □ □ ✓
JSA_23 JSA_17 4 ✓ □ ✓ □ ✓ ✓
JSA_23 JSA_17 7 ✓ □ ✓ □ □ ✓
JSA_06 JSA_02 3 ✓ □ □ □ □ □
JSA_19 JSA_21 3 ✓ ✓ ✓ ✓ ✓ ✓
JSA_19 JSA_21 6 ✓ ✓ ✓ ✓ □ ✓
JSA_17 JSA_19 2 ✓ ✓ □ □ □ □
JSA_17 JSA_19 5 ✓ ✓ □ □ ✓ ✓
JSA_17 JSA_16 5 ✓ ✓ ✓ ✓ ✓ ✓
JSA_16 JSA_17 4 □ □ ✓ □ □ ✓
JSA_16 JSA_17 7 □ □ ✓ □ □ ✓
JSA_19 JSA_26 5 □ □ □ ✓ ✓ □
JSA_19 JSA_26 6 □ □ □ ✓ ✓ □
Sustainability 2024, 16, 9277 23 of 28
5.4. Discussion
The key performance metric of the JSA synchronization model in Scenario 1 was its
ability to accurately identify hazards during SIMOPS with a high recall rate of 97.52%.
The recall rate indicates that the model effectively identifies hazards and can contribute
to preventing risks during SIMOPS. The excellent performance metrics of the model can
be attributed to the improvements to the existing JSA data via the R-JSA methodology.
The improved input data played a crucial role in improving the model output results.
Nonetheless, there were three missed cases (FN) and one incorrectly identified case (TP).
The reasons can be attributed to omissions and errors. Although SMEs can identify missing
information in JSAs during the final review, the model cannot generate new information
from the R-JSA, leading to omissions. The TP was attributed to incorrect data entry
by the responsible worker for the direction attribute in the R-JSA. The quality of input
data significantly impacts the results, highlighting the need for continuous efforts to
improve data completeness and accuracy. The results of Scenario 1 affirmed Moravec’s
paradox [66]—computers easily perform complex calculations while humans excel in
intuitive understanding. Thus, better outcomes can be obtained by complementing the
strengths of both the model and humans.
Scenario 2 demonstrated that the SIMOPS process with multiple experts is useful
in identifying hazards in SIMOPS via the differences between individual and integrated
identification results by SMEs. However, the results highlighted the limitation of the
SIMOPS process in responding immediately to variable situations such as unplanned tasks,
thereby confirming the utility of the model.
During interviews, SMEs reported that they could pay sufficient attention to identify
and correct missing or incorrect information in the detailed target–source list and visual-
izations obtained from the model in Scenario 1. In contrast, despite sufficient information
on the existing and additional tasks, the identification rate was low in Scenario 2. The
SMEs reported that they repeatedly rechecked the information on surrounding tasks while
reviewing additional tasks with drawings and JSAs, making inference difficult due to the
diversity of hazard attribute variables. The results of Scenario 2 highlight the limitations
of human memory and inference ability. These results are supported by research findings
which indicate that working memory and inference share cognitive capacity. Working mem-
ory refers to a cognitive system that maintains a certain amount of information temporarily,
while inference refers to the act of drawing conclusions from given information. As the
number of variables increases, the increasing complexity of interrelationships leads to poor
inference [67].
The following insights were obtained from both scenarios. The results obtained
in this study indicate that HIRAS can help reduce the load on working memory from
a cognitive capacity perspective and help support inference on inter-task relationships.
Therefore, safety managers can focus on productive work, such as identifying missed
hazards, coordinating tasks, and developing countermeasures based on the provided
information. Moreover, HIRAS can be used for the rational allocation of resources, such
as effort, time, and cost, to manage hazards. Job managers and workers can identify the
target job they are performing, check the source job information, and use the information
for mutual coordination. A limitation of HIRAS is that some items may be omitted due to
the quality of JSAs. However, as JSAs are evaluated annually and updated as needed, the
likelihood of missing items is expected to gradually decrease.
The relevance and contribution of this study can be summarized as follows. First, by
demonstrating that hazards in SIMOPS can be identified using JSAs, this study shows that
the limitations of JSAs pointed out in previous studies can be addressed. Thus, JSAs can be
used not only as a tool for analyzing individual task risks but also as an effective tool for
identifying hazards in SIMOPS environments. Second, previous research on identifying
hazards in SIMOPS has focused on general tasks because they are based on information
derived from expert judgment. In contrast, this study uses hazard information identified
by the managers responsible for each task, including the specificity of individual tasks and
Sustainability 2024, 16, 9277 24 of 28
6. Conclusions
6.1. Summary and Contributions
This study proposed a new safety management tool, “HIRAS,” to identify and assess
hazards between SIMOPS during plant maintenance work. The traditional JSA methodol-
ogy is useful for the safety management of individual tasks; however, managing the safety
of surrounding tasks via JSA is challenging. Industrial sites continue to evolve, becoming
more complex and variable. Hence, research on methods for ensuring worker safety and
minimizing potential hazards is essential when it comes to responding to the changes in
industrial environments. The framework developed in this study can identify and assess
the impacts of hazards resulting from interactions between tasks by synchronizing existing
JSA information temporally and spatially. The R-JSA method was developed herein to sys-
tematically standardize unstructured data, such as task locations and hazard information.
The results of the R-JSA method were used to develop the R-JSA synchronization model for
task synchronization and hazard impact analysis. The S-RA formula was used to prioritize
the results generated by the model based on the risk levels. The HIRAS framework was
validated through two scenarios, demonstrating its utility for SIMOPS safety management.
The contributions of this study are summarized in the following three points. First,
it proposes a new approach that extends the use of JSA beyond individual task safety
management to include the safety management of surrounding tasks. This suggests that
by leveraging the domain knowledge of task managers and synchronizing JSAs, hazards
in surrounding tasks can be identified and assessed. Second, it enables safety managers
to direct their focus toward preventive tasks. The visualization of target and source jobs
and detailed lists helps reduce the cognitive burden of identifying hazards in complex and
variable environments. Finally, by using easily accessible and regularly updated JSAs, it
offers small workplaces with limited safety management personnel an effective way to
enhance safety during SIMOPS. Major accidents can be prevented by improving safety in
plant maintenance work environments wherein multiple tasks are performed simultane-
ously. Ultimately, the results of this study are expected to contribute to sustainable business
management and the protection of worker lives and health in hazardous environments.
The HIRAS developed in this study represents a significant step forward, but further
research is required to address its limitations and realize its full potential. Future research
should focus on integrating HIRAS with existing enterprise systems, such as ERP and
safety management systems, to facilitate its practical application in industrial settings.
Although this study focused on industrial plant maintenance, the results are applicable
to other fields using JSA. We expect that future research based on this study on preventing
SIMOPS accidents will contribute to improving safety levels in industrial sites and corporate
sustainability management.
Author Contributions: The contributions of the authors for this article are as follows: Conceptualiza-
tion, S.-J.K., S.-W.C. and E.-B.L.; methodology, S.-J.K., S.-W.C. and E.-B.L.; software, S.-J.K.; validation,
S.-J.K., S.-W.C. and E.-B.L.; formal analysis, S.-J.K. and S.-W.C.; investigation, S.-J.K. and S.-W.C.;
resources, S.-J.K., S.-W.C. and E.-B.L.; data curation, S.-J.K.; writing, original draft preparation, S.-J.K.
and S.-W.C.; writing, review and editing, S.-J.K., S.-W.C. and E.-B.L.; visualization, S.-J.K. and S.-W.C.;
supervision, E.-B.L.; project administration, E.-B.L. All authors have read and approved the final
version of the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Informed consent was obtained from all subjects involved in the
study.
Data Availability Statement: The original contributions presented in the study are included in the
article, further inquiries can be directed to the corresponding author.
Acknowledgments: The authors of this study would like to thank POSCO for their informational
support and technical cooperation. The views expressed in this paper are solely those of the authors
and do not represent those of any official organization.
Conflicts of Interest: The authors declare no conflicts of interest.
Abbreviations
The following abbreviations and parameters are used in this paper:
ERP Enterprise Resource Planning.
FMEA Failure Modes and Effect Analysis.
GPT Generative Pre-trained Transformer.
HAA Hazard-Affected Area.
HAZOP Hazard and Operability Studies.
HIRAS Hazard Identification and Risk Assessment of Simultaneous operations.
HL Hazard Layer.
HZ Hazard Zone.
IMCA The International Marine Contractors Association.
ISO International Organization for Standardization.
JSA Job Safety Analysis.
KOSHA Korea Occupational Safety and Health Agency.
PoC Proof of Concept.
R-JSA Relation-oriented JSA method.
RPN Risk Priority Number.
SIMOPS SIMultaneous OPerations.
S-RA SIMOPS Risk Assessment.
TBM ToolBox Meeting.
TZ Task Zone.
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