Risk Assessment of Non-Destructive Testing in Smart Production Lines Using Risk Matrix and HAZOP Approach

In industrial sectors involving welding and metallic structures, ensuring the safety and reliability of components is critical for operational performance. Non-destructive testing (NDT) plays a key role in defect detection and structural integrity assessment; however, the increasing complexity of smart manufacturing environments introduces new sources of risk that are not adequately addressed by traditional approaches. This study develops an integrated risk assessment framework for NDT processes in smart production lines by combining the risk matrix method with the Hazard and Operability Study (HAZOP). Four major NDT techniques—ultrasonic testing (UT), radiographic testing (RT), magnetic particle testing (MT), and liquid penetrant testing (PT)—were systematically analyzed. Risks were identified across human, environmental, equipment-related, and digital system factors, and evaluated based on likelihood and severity criteria. The results indicate that human-related risks, particularly interpretation errors and operator fatigue, represent the most critical risk category, reaching the highest risk levels. Equipment-related failures, including calibration errors and sensor malfunctions, and environmental conditions were also found to significantly affect inspection reliability. In addition, emerging risks associated with digital systems—such as automated analysis errors and data transmission failures—were identified as important contributors in Industry 4.0 environments. The integration of HAZOP with the risk matrix enabled a more comprehensive understanding of root causes and improved the prioritization of critical risks. The proposed framework provides a practical and scalable approach for enhancing inspection accuracy, reducing operational risks, and supporting decision-making in smart manufacturing systems.