Integrating lean principles and fuzzy bow-tie analysis for risk assessment in chemical industry

Faisal Aqlan, Ebrahim Mustafa Ali

Research output: Contribution to journalArticlepeer-review

99 Scopus citations


In this research, a framework combining lean manufacturing principles and fuzzy bow-tie analyses is used to assess process risks in chemical industry. Lean manufacturing tools and techniques are widely used for eliminating wastes in manufacturing environments. The five principles of lean (identify value, map the value stream, create flow, establish pull, and seek perfection) are utilized in the risk assessment process. Lean tools such as Fishbone Diagram, and Failure Mode and Effect Analysis (FMEA) are used for risk analysis and mitigation. Lean principles and tools are combined with bow-tie analysis for effective risk assessment process. The uncertainty inherent with the risks is handled using fuzzy logic principles. A case study from a chemical process industry is provided. Main risks and risk factors are identified and analyzed by the risk management team. Fuzzy estimates are obtained for the risk factors and bow-tie analysis is used to calculate the aggregated risk probability and impact. The risks are prioritized using risk priority matrix and mitigation strategies are selected based on FMEA. Results showed that the proposed framework can effectively improve the risk management process in the chemical industry.

Original languageEnglish (US)
Pages (from-to)39-48
Number of pages10
JournalJournal of Loss Prevention in the Process Industries
Issue number1
StatePublished - May 2014

All Science Journal Classification (ASJC) codes

  • Control and Systems Engineering
  • Food Science
  • Chemical Engineering(all)
  • Safety, Risk, Reliability and Quality
  • Energy Engineering and Power Technology
  • Management Science and Operations Research
  • Industrial and Manufacturing Engineering


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