Introduction: industrial environments due to their nature are subject to serious risks and damages, and in proportion to growing technology, these risks and damages are potentially developing. This study aimed to assess the risks and impacts of non-flammable solvent replacement on risk assessment code using William Fine’s method in a plastic factory and evaluate the effectiveness of alternative risk assessment and ultimately replace the code and introduce a method to economically explain the removal of a threat.

Methods: This was an interventional study in which the risks were investigated in all units of a plastic factory by JSA method, and then the risks were analyzed by HSE staff using William Fine’s method. In one case, intervention (replacement) was performed and RAC 1& 2 were calculated. Data were analyzed using SPSS (ver. 16).

Results: Among 9 main jobs (tasks) of the plastic company, 79 risks were detected. The maximum risk code was related to solvent fire (risk code: 300), and then being trapped between the rollers (risk code: 180). In this study workers of production unit and printing disposable tablecloths, were exposed to higher risks compared to other company worker due to exposure to various risks with different risk codes.

Conclusion: The results of this study indicated that replacement as an engineering method is one of the most fundamental methods to reduce the number of risks, and with this method we can reduce, control or eliminate the amount of dangers of hazardous environments and William Fine’s method is a practical way to estimate the related costs.