Business Intelligence-Based Risk Analysis Approach to Prevent Accidents in Overhead Crane Operations

Abstract

Overhead crane operations remain a high-risk activity in heavy manufacturing, yet safety management often relies on static assessments that fail to capture real-time operational dynamics. In developing economies such as Indonesia, a significant digital gap hinders the adoption of high-cost IoT solutions, leaving safety data fragmented and reactive. This study aims to bridge this gap by developing and validating a Business Intelligence (BI) Safety Dashboard that utilizes bridge technologies, defined as cost-effective digital solutions that leverage existing administrative and operational data instead of dedicated IoT infrastructure, to provide real-time predictive risk insights. Following a Design Science Research (DSR) framework, a three-year longitudinal study (2024–2026) was conducted at a metal fabrication facility in West Java. A Weighted Dynamic Risk Score (WDRS) was formulated using Data Analysis Expressions (DAX), integrating incident logs, maintenance records, and operator certification data into a unified star schema model. The results demonstrate a 95% reduction in data processing time and a 30% increase in near-miss reporting. The proposed artifact successfully identified critical risk outliers, such as Crane 08 (WDRS = 8.3), and generated spatiotemporal heatmaps that pinpointed specific risk hotspots within the facility. These findings confirm that the BI Dashboard is a feasible and highly practical solution for resource-constrained environments, providing a scalable blueprint for Indonesian SMEs to achieve Industry 4.0 safety standards by leveraging existing administrative data for predictive maintenance and proactive safety interventions.