Design Issues and Their Associated Health Hazards from Metal Fumes During the Welding Process

This paper presents the various design issues and health hazards associated with the welding process. A detailed human-machine environment (HME) block diagram was constructed to analyze the welding process. Based on the HME diagram, field visit and literature review, a detailed set of questions was framed. The design issues and health hazards were compiled from a broad group of welders around Tezpur, India. The questionnaire consisted of parameters like length of welding exposure, welding duration, welding flashes, dust and fumes in welding, ventilation available, usage of protective equipment, and various symptoms and issues faced by welders. Based on the response received, the following was observed. In most cases, the welders used welding goggles and shields to protect them from welding sparks, debris, and ultraviolet rays. It was observed that the welders were unaware of the health hazards caused by metal fumes generated during the welding process and its impact on the welder's health. No protective equipment was used by welders to prevent metal fume inhalation. Thus, welders require an immediate occupational safety guideline to be implemented in the workspace to prevent metal fume inhalation. The concepts were developed by integrating the TRIZ principles and morphological charts. Based on the above factors, the authors have presented various product concept design alternatives to prevent metal fume inhalation among welders.