Job risk assessment system and operational framework improvement for chemical accident prevention: A study and pilot application of manufacturing industry

Abstract Outsourced maintenance in South Korea's chemical industry exposes subcontractor workers to complex risks such as fires, explosions, and chemical exposure, as existing safety standards often fail as practical control systems. This study and pilot application addresses these gaps through a case study of a manufacturing company, implementing an improved operational framework centered on a collaborative, job safety analysis (JSA)‐based risk assessment process. This framework institutionalizes a joint review process between the primary contractor and subcontractors and is supported by a digital platform that integrates JSA results with work permits and toolbox meetings in real‐time. Following its implementation, the new system yielded substantial improvements in safety performance: the number of lost‐time accidents decreased from 19 to 5, and the Lost Time Injury Rate (LTIR) fell dramatically from 0.289 to 0.04 within a year. The findings demonstrate that integrating a collaborative assessment framework with a digital system creates a practical, effective safety management model. This study provides an empirically validated framework for enhancing safety in outsourced operations within the chemical sector and other high‐hazard industries.