• Narendra Shivajirao Deshmukh

Material handling forms the backbone of industrial operations, influencing the overall performance, safety, productivity, and cost-effectiveness of manufacturing and construction projects. Despite the adoption of modern equipment and advanced safety guidelines, industries continue to face major risks such as musculoskeletal injuries, material damage, equipment malfunction, and workplace accidents. This research paper provides a detailed risk analysis of material handling processes using structured techniques including Hazard Identification (HAZID), Failure Mode and Effect Analysis (FMEA), and the Risk Assessment Matrix. Data was collected from industrial case studies, operator interviews, equipment observations, and historical safety records. Results indicate that manual lifting errors, equipment collisions, and improper load storage are the primary contributors to accidents. The study proposes comprehensive mitigation strategies such as ergonomic intervention, process automation, operator certification training, predictive maintenance, and structural improvements in workflow layout. The findings aim to support industries in minimizing risk exposure and enhancing safety culture.

Material Handling, Risk Analysis, HAZID, FMEA, Industrial Safety, Workplace Hazards, Risk Mitigation

"“ RISK ANALYSIS OF MATERIAL HANDLING SYSTEM”", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.12, Issue 12, page no.a572-a577, December-2025, Available :http://www.jetir.org/papers/JETIR2512076.pdf

"“ RISK ANALYSIS OF MATERIAL HANDLING SYSTEM”", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.12, Issue 12, page no. ppa572-a577, December-2025, Available at : http://www.jetir.org/papers/JETIR2512076.pdf