Analysis of Safety 5.0 in Li-ion Battery Manufacturing within Industry 5.0: Preventing the Domino Effect

Abstract

Lithium-ion batteries store a large amount of energy, which can create serious safety risks such as domino-effect failures, where one problem triggers another. Traditional risk assessment methods mainly identify hazards but often fail to show how modern manufacturing processes are connected to these risks. This study addresses this gap by developing a simple and unified safety assessment framework using HIRA, AHP, and TOPSIS methods. A questionnaire survey was conducted with ten experts from battery manufacturing and industrial safety to collect data. The AHP analysis showed that domino-effect potential (0.42) and severity (0.27) are the most important factors in evaluating risks, while the consistency ratio (0.09) confirmed that the experts’ judgments were reliable. The identified hazards were then ranked using the TOPSIS method. The results showed that thermal runaway is the most critical hazard with a score of 0.89, followed by fire and explosion with a score of 0.78 because of their high intensity and ability to spread quickly. These findings emphasize the need to consider chain reactions in industrial safety assessments. The proposed framework can also support advanced technologies such as AI-based and predictive risk management systems.