DEVELOPMENT OF RACI MATRIX FOR COMPLETE MACHINE LIFECYCLE

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 02 | Feb 2023 www.irjet.net p-ISSN: 2395-0072
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 520
DEVELOPMENT OF RACI MATRIX FOR COMPLETE MACHINE LIFECYCLE
Mohammad Arshad1, Sandeep Saha2, Sanjay Kumar Sahu3
1M.Tech Scholar, Bhilai Institute of Technology, Raipur, Chhattisgarh, India
2,3Assistant Professor, Dept. of Mechanical Engineering, Bhilai Institute of Technology, Raipur, Chhattisgarh, India
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Abstract - A RACI Matrix or Responsibility Assignment
Matrix is a matrix of all activities or decision-making
authorities undertaken for any process. Ateachintersection of
activity and role it is possible to assign someone responsible,
accountable, consulted or informed for that activity or
decision. In this research, the process of capacitor
manufacturing is observed and safety critical machines are
identified for the same. Then for those safety criticalmachines
different stages of life cycle are identified. Once the
identification of machine is completed with different stages, a
list of safety related activities and list of stakeholders,
associated with the task or activity, is created. To identify the
stages, activities and different stakeholders, a risk assessment
study was carried out to find the safety critical equipment to
define the criticality of the task and of the machine. On finding
the risks, roles and responsibilities were assigned for thesame
to ensure proper and safe workingoperationof theequipment.
The main objective of this research is to ensure accountability
is placed with the person who really can be held accountable
for specific work and safe work practices. It includes all
routine and non-routine activities involved in capacitor
manufacturing process.
Key Words: RACI, Safety Accountability, Responsibility
1.INTRODUCTION
RACI Matrix or Responsibility Assignment Matrix is a safety
management tool designed to assign tasks, activities,
responsibilities, accountability, decision making, support to
team members of a process/project and clarify expectations
on the level of their participation. This tool is used for
identifying roles and responsibilitiesandavoidingconfusion
over those roles and responsibilities during project. To
ensue collaboration and project success, it is crucial for all
stake holders to understand their roles and responsibilities
and those of other project members.
It is an element of the safety assurance program which
integrates various safety management tools to assure safety
of the employee. There are fifteen elements in this program
which address the safety issues in organization at different
levels. It has four levels in it namely People Certification &
Authentication, Engaging Hearts & Mind in Safety,
Equipment Certification & Authentication and Safety
Assurance Program. All four level starts from creating safe
environment, creating awareness among employees
regarding safety at workplace, creating a system to check if
the safety related issues have been addressed and
maintaining a level of safety for the employees.
RACI Matrix is one of the key safety management tools used
in assuring safety of employees. It uses a work breakdown
structure and organizational structuretolink deliverablesor
activities to resources
In Responsibility Assignment Matrix, a process or activity is
defined step by step and for every step or task specific roles
are assigned according to the needs. It ensures each activity
have accountabilityfixedwiththerespectivepersonwho can
be held accountable for specific work and safe work
practices. It involves representatives from all departments
and information is being shared in between them. The
purpose of a RACI Matrix is to eliminate confusion between
departments and individuals regarding their roles and
responsibilities.
1.1 Elements
Stakeholders – Any individual or a group of individuals
connected to a given task, directly or indirectly, and whose
involvement affects the outcome of the desired task will be
called as a stakeholder. Other than the ones performing the
task, there are many individuals and many departments
which work together to form a communication model and
helps in performing the task effectively.
Operations – For this project the focus is to identify various
stages of machine lifecycle in which safety related issues are
faced and are addressed.Startingfrompre-commissioningto
decommissioning of the machine there are seven stages in
which the activities are identified and roles are defined for
the same.
- Pre-commissioning Inspection
- Commissioning
- Daily Startup Inspection
- Standard Operation
- Maintenance Operation
- Modification
- Decommissioning

1.2 Assigning Roles and Responsibility
Responsible – Responsible is one who will perform the
defined task and will have required knowledge of the
operation to perform the task. He should know the basic
safety awareness about the operation and PPE and standard
operating procedure knowledge. The role demands the
individual tohaveunderstandingaboutwhattodoandwhom
to contact in case of an emergency.
Accountable – An individual who will havetotalauthority
over the operation and who can give command to perform
the task. He should also have a total understanding of the
work permit system to perform a task, if required. He is one
who will have thorough knowledge of operations to be
performed. He will decide by whom the task will be
performed and how it is being performed. He should also
have knowledge of operations safety training and will
provide the same to the employees before starting the
operation. He will have a thorough knowledge of required
rules and regulationsand will providethesametoemployees
along with manuals and checklist.
Consulted – An individual who is an expert inhisfieldand
have a thorough knowledgeandexperienceoftheworkbeing
performed. He should provide solution to any safety related
problem.
Informed – The one who is not directly connected to task
or who has no direct effect ontask completionbutisrequired
to get an update about the task. The individual with this role
is generally a higher authorityorseniordepartment.Heisthe
head of the team concerned with the section of the task. He is
one who gives the order to do the task and is informed once
the task is completed.
Assigning rolesshould providebothpositiveandnegative
aspects of the tasks to be performed. Identifying and
promoting individualaccountabilitiescanraiseselffulfilment
and can lead to enhanced performance. The actual pattern of
responsibility assignment depends on the management
body’s administrative structure and any legally defined
accountability.
Too many responsibilities assigned wastes available
expertise and limit its further development in any local or
field office
2. LITERATURE REVIEW
Jesús Álvarez-Santos, José-Á. Miguel-Dávila, Liliana
Herrera, Mariano Nieto (2018): “Safety Management System
in TQM environments” The journal aimed at knowing the
conditionsthatacceleratetheadoptionofsafetymanagement
system either under principles, beliefs and values of TQM or
because of the implementation and application of essential
safety management technique. Safety managementsystemis
a management model that groups functions, responsibilities,
practices, procedures and processes for risk prevention.
Assumption of responsibilityincorporates the principlesofa
risk prevention policy.
T. Kontogiannis, M. C. Leva, N. Balfa (2017): “Total Safety
Management: Principles, Processes and Methods” The
integration of safety with other management systems (e.g.,
quality, environment and productivity) has been addressed
either at a strategic level or a standardization level. This
article looksat the coordination between businessprocesses
that arecommontothesemanagementsystemsandproposes
several principles of Total Safety Management based on
earlier studies and a three-year experience with a European
project. Four safety processes are proposed which are
compatible with ISO 31000 & CCPS Standards 2008 and
principles of TSM are discussed briefly. In general, a TSM
approach should consider risk assessment within the
framework of a functional system model that describes both
the activities of operators and the business processes that
support human performance(i.e.,supplies,tools,workplaces,
training). Human operations are analyzed in terms of tasks,
information needs, decisions and coordination.
Gudela Grote (2015): “Promoting safety by increasing
uncertainty – Implications for risk management” In this
research paper processes are proposed as a criterion for
decisiononreducing,maintainingandincreasinguncertainty.
Necessity to manage uncertainty and its impact on control
and accountability. Reduced uncertainty results in stable
systems and maximum control whereas increased
uncertainty leads to flexible system and self-organization
Sidney W.A. Dekker (2015): “The bureaucratization of
safety” Bureaucratic accountability refers to the activities
expected of organization members to account for the safety
performance of those theyare responsiblefor(e.g.unit,team,
site). Bureaucratization of safety has brought benefits,
including a reduction of harm, standardization,transparency
and control. It has been driven by regulation, liability and
insurance arrangements, outsourcing and contracting, and
technologies for surveillance and data storage.
Oregon OSHA:SafetyandHealthManagement–theBasics
Gives to basic understanding about safety management
system and basic definition of responsibility, accountability
and difference between the two. The research paper
concludes that production supervisors are held accountable
for safety, health and ergonomics in their departments. Top
management is held accountable for facility safety
performance though their own performance evaluations.
Overview for Management of Change based on Business
Process Model of Plant Lifecycle. This journal talks about the
accidents caused by uncontrolled changes which could have
been monitored easily. Various plant lifecycle stages are
discussed here and many activities are identified over the
plant lifecycle such as process hazard analysis, training, and
so on are required for the changes.

2.1 Objective of the Project
 Detailed study about the machine and process and to
understand every single activity involved in the process
by breaking down it in simple stages.
 Identifying activities and tasks related to the process and
the machine at every stage.
 Assigning rolesand responsibility to individualsinvolved
with the process and to create a proper communication
model.
 To eliminate and avoid confusions between different
departments regarding their roles.
 To know about every safety issue in every activity
associated with the project and the steps taken to
eliminate or reduce it.
3. METHODOLOGY
Current research methodology to obtain the desired RACI
Matrix is demonstrated in figure below:
Figure 1 Methodology of project
4. RESULTS
4.1 Identification of Safety Critical Machines
The first step of the project was to identify safety critical
machines for which RACI Matrix was to be created. To
complete this task, Occupational Risk Assessment of the
capacitor manufacturing process was carried out. The
purpose of the risk assessment was to find out the high-risk
activitiesand criticaloperationmachinesandtofindinvolved
dangers in it. Mitigation plan for the same was prepared and
responsibilities were assigned.
Table 1: Probability of occurrence
Probability
Level
Order of magnitude of Probability or
Exposure duration
3- Probable Daily to monthly event (larger exposure
durations)
2- Improbable Monthly to annual event (exposure remaining
limited in duration)
1- Very
improbable
Events occurring annually or every few years
(short and rare exposure)
The severity of injuries or damage to health can be
estimated by considering reversible injuries, irreversible
injuriesordeath.Therecommendedclassificationisshownin
the table 2. Probability of occurrence is estimated using the
least favorable case. It is recommended to ensure that three
factors namely Frequency of exposure, occurrence of
hazardous events and possibilities of avoiding the harm are
considered as mentioned in table 1.
Risk matrix is used to determine the level of riskbasedon
the probability of occurrenceofthehazardandtheseverityof
the harm. On the bases of risk assessment carried out for the
capacitor manufacturing process, following points are
observed:
Table 2: Severity of occurrence
Severity level Type of bodily harm considered
3- Very serious Amputation major fractures; poisoning multiple
fractures; fatal injury, occupational cancer; other
illnesses reducing life expectancy; fatal acute
illnesses. Partial permanent incapacity to work.
2- Quite serious Lacerations and wounds; burns; concussion;
serious sprains; minor fractures; deafness;
dermatitis; asthma. Poor health leading to a minor
but permanent disability; or temporary incapacity
to work.
1- Minimal Incidents nearly without injury or with superficial
injuries; small cuts and bruises;irritationofeyesby
dust; discomfort or problem with temporary
discomfort of one or several people. Benign events
or accidents that are recorded.
Table 3: Risk Rating Matrix
Severity
Probability
Minimal Quite serious Very serious
Probable
3- Moderate
risk
4- Substantial
risk
5- Intolerable
risk
Improbable
2- Tolerable
risk
3- Moderate
risk
4- Substantial
risk
Very
Improbable
1- Negligible
risk
2- Tolerable
risk
3- Moderate
risk

On the bases of risk assessment carried out for the
capacitor manufacturing process, following points are
observed:
 Winding area consisted of activities categorized in five
groups. Total 31 risks were identified for winding
operations out ofwhich2risksaresignificant.Thehighest
risk rating obtained by winding machine is 3.
 Spraying area consisted of activities categorized in seven
 Element Testing areaconsistedofactivitiescategorizedin
three groups. Total 17 risks were identified for winding
operations out of which 1 risk is significant. The highest
 Support assembly line consisted of activities categorized
in 9 groups. Total 25 risks were identified for winding
 Resin Filling areaconsisted of activities categorizedinsix
 Seaming operation consisted of activities categorized in
ten groups. Total 19 risks were identified for winding
operations out of which 1 risk is significant. The highest
 Capacitor testing area (Infinity and Koti) consisted of
activities categorized in eleven groups. Total 63 risks
were identified forwinding operationsoutofwhich1risk
is significant. The highest risk rating obtained by winding
machine is 3.
The various risks identified for safety critical machines
during standard operations are identified. During winding
operations two safety risks were identified and control
measures or counter measures are defined for the same. In
the same manner for spraying area the five risks were
identified with moderate risk level. Similarly, for testing
operation, seaming operation and capacitor testing
operations one risk is identified for each operation as
moderate level risk and control measures are placed.
Table 4 Risk Assessment Sheet for Winding Operation
Table 5 Risk Assessment Sheet for Spraying Operation

Table 6 Risk Assessment Sheet for Element Testing Operation
Table 7 Risk Assessment Sheet for Seaming Operation
Table 8 Risk Assessment Sheet for Capacitor Testing Operation
4.2 List of Activities and Stakeholders
After finding the all safety critical equipment used in
capacitor manufacturing process, the next step requires the
identification of all activities associated with the machine
during whole life cycle and to find different stakeholders for
different stages of machine lifecycle.
Table 9 Identified Departments and Stakeholders
Department Stakeholders
Production
Production Operator
Production Supervisor/ Shift in-
charge
Production Manager
CS&Q Quality Manager
Maintenance
Maintenance Manager
Maintenance Technician
Methods Department Methods Head
SPS & CI Schneider Performance System & CI
Head
EHS EHS Manager
EHS Executive
Supply chain
Management
Warehouse Manager
Supply chain Manager
IFM
Facility Manager
Housekeeping Personnel
HR Department HR Manager
Plant Head
To find the list of activities various documents were studied
and observations were made.
The documents required for finding the list of activities are:
 Operations Work Standards
 Standard Operating Procedure
 Machine Manual from Original Equipment Manufacturer
 Job Breakdown Sheets
 Occupational Risk Assessment Sheets
 OCP and OHSMP
A stakeholder is one who’s involvement, directly or
indirectly, affects the outcome of the process. There are
various departments and individuals from where the
stakeholders are find. To ensure collaboration and project
success, it is crucial for all project stakeholders to
understand their roles and responsibilities and those of
other project members. This is especially important when
project teams are more complex due to their large size,
involvement of distributed team members or reliance on
staff from multiple departments.

RACI Guidelines:
 Avoiding multiple levels of oversight and working on one
level.
 Maintaining chart fluidity-makingchangesasneededand
letting people know when things change.
 Assigning only one accountable per task. There shall
never be two persons accountable for a single task
 Ensuring accountable assignees have authority to ensure
the task is complete.
 Avoid too many consultants as they may take too much
time while too few can damage the performance
 Inform everyone with role of their assignment
 If too many people must be assigned consulted, evaluate
whether one person can be assigned who talk with other
involved.
4.3 Assigning Roles and Responsibilities
4.3.1 Winding Area
Table 10 No. of activities for winding machine
Metar Winding Machine
Sr. No Stages of operation No. of
Activities
1 Pre-commissioning Inspection 35
2 Commissioning 31
3 Daily Startup Inspection 17
4 Standard Operation 27
5 Maintenance Operation 30
6 Modification 24
7 Decommissioning 33
Departments
involved
CS&Q Executive Manager
Production Operator Supervisor Manager
Methods Executive Manager
EHS EHS Executive EHS Manager
Maintenance Executive Manager
HR Asst. Manager Sr. Manager
IFM Housekeeping
Staff
Housekeeping
Supervisor
IFM
Manager
Warehouse Operator Supervisor Manager
Similarly, the no. of activitiesand involvementofdepartment
were identified for spraying machine, ECACtestingmachine,
riveting machine, HV Lid testing, resin filling machine,
seaming machine, capacitor testing machine.
RACI Matrix as a sample for Pre-commissioning inspection,
commissioning and Daily Startup inspection is attached in
the Annexure I and Annexure II.
5. CONCLUSIONS
Risk Assessment has been carried out for all the machines
involved in capacitor manufacturing process to identify
critical machines. The process involved the detailedstudy of
every machine and activity and finding related activitiesand
stakeholders involved in the task. Assigning roles and
responsibilities is done for all safety critical machines at
different stages of life cycle. Steps undertaken to create the
RACI chart are:
 Identified the project tasks – meeting the stakeholders
to develop the activities involved. Maintenance of RACI
matrix as a task is to be done.
 Identified the roles – roles identified and allocated to
stakeholders associated with the tasksandclarifyingthe
resource allocation. This step helps in eliminating the
confusion over the roles and responsibilities of
employees.
Critical machines found during the study are as follows
 Winding Machine – for winding MPP film on core
 Spraying Machine- Spraying zinc coatingonsidesof
the elements
 ECAC Testing machine- Testing the quality of
elements
 Riveting machine – Preparation of capacitor lid
using hydraulic energy
 HV Lid testing – Checking the quality and durability
of lids under high voltage
 Resin filling machine – Filling the resin in capacitor
containers
 Seaming machine – Sealing and seaming the
capacitor can
197
Table 11 Department involved in winding operation

 Capacitor testing machine – Final checking of the
capacitors before packing
The study of following machines was done and total 1240
safety related activities are observed and roles are assigned
for the same. The results of risk assessment showsthatmost
of the risks observed were of risk rating 2 and were
tolerable. Control measures were identified to further
minimize those risks and to bring it down to a risk ratingof1
Table 12 Risk Assessment Sheet
Sr.
No.
Machine
No. of activities
identified
Risk Rating for
the machine
1 Winding Machine 197 3
2 Spraying Machine 256 3
3 Element Testing
Machine
207 3
4 Riveting Machine and
Lid TestingMachine
195 3
5 Seaming Machine 191 3
6 Resin Filling Machine 183 2
7 Capacitor Testing
Machine
196 3
REFERENCES
1. T. Kontogiannis, M. C. Leva, N. Balfa; “Total Safety
Management: Principles, Processes and Methods”
Journal of Safety Science, volume 100,PartB(December
2017), page no 128-142.
2. Gudela Grote; “Promoting safety by increasing
uncertainty – Implicationsforrisk management” Journal
of Safety Science, Volume 71, Part B (January 2015),
Page no71-79.
3. Jesús Álvarez-Santos, José-Á. Miguel-Dávila, Liliana
Herrera, Mariano Nieto;“Safety Management System in
TQM environments” Journal of Safety Science, volume
101(2018), page no 135-143.
4. Marko Gerbec; “Safety change management – A new
method for integrated management of organizational
and technical changes” Journal of safetyscience, Volume
100(December 2017), Page no. 225-234
5. Yuling Lia, Frank W. Guldenmund, “Safety management
systems: A broad overview of the literature”; Journal of
Safety Science, Volume 103(2018), Page no. 95-123.
6. Kazuhiro Takeda, Hideo Saito, Yukiyasu Shiamad, Teiji
Kitajima, Tetsuo Fuchino, Yuji Naka; “Overview for
ManagementofChange basedonBusinessProcessModel
of Plant Lifecycle” Journal of Process Safety, Volume
23(2013)
7. Safety and Health Management – the Basics, OSHA,
Oregon OSHA.
8. Project Management in Product Development, George
Ellis.
9. ISO 12100-2010 - Safety of Machinery- General
Principles for Design- Risk assessment and risk
reduction. www.iso.org

Annexure 1
RACI Matrix for Pre-commissioning inspection of Winding Area

Annexure 2
RACI Matrix for Commissioning inspection & Daily Startup inspection of Winding Area

DEVELOPMENT OF RACI MATRIX FOR COMPLETE MACHINE LIFECYCLE

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