Citation :

Pradeep Piplotiya, Vijay Shankul, "Analysis of Safety 5.0 in Li-ion Battery Manufacturing within Industry 5.0: Preventing the Domino Effect," International Journal of Recent Engineering Science (IJRES), vol. 13, no. 4, pp. 22-33, 2026. Crossref, https://doi.org/10.14445/23497157/IJRES-V13I4P103

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.

Keywords

AHP, DE, Industry 5.0, HIRA, Li-ion, TOPSIS.

References

[1] S.C. Chen, C.C. Wan, and Y.Y. Wang, “Thermal Analysis of Lithium-Ion Batteries,” Journal of Power Sources, vol. 140, no.1, pp. 111-124, 2005.
[CrossRef] [Google Scholar] [Publisher Link]

[2] Thomas L. Saaty, “Decision Making with the Analytic Hierarchy Process,” International Journal of Services Sciences, vol. 1, no. 1, pp. 83-98, 2008.
[CrossRef] [Google Scholar] [Publisher Link]

[3] Donal P. Finegan et al., “In-Operando High-Speed Tomography of Lithium-Ion Batteries during Thermal Runaway,” Nature Communications, vol. 6, no. 1, pp. 1-10, 2015.
[CrossRef] [Google Scholar] [Publisher Link]

[4] Cheng Jin, “Brief Talk about Lithium-ion Batteries’ Safety and Influencing Factors,” IOP Conference Series: Materials Science and Engineering, vol. 274, no. 1, pp. 1-5, 2017.
[CrossRef] [Google Scholar] [Publisher Link]

[5] Angela Saini, and Micheal Austin, “Manufacturing Li-Ion Batteries for Safety and Performance,” MRS Bulletin, vol. 42, no. 6, pp. 414-415, 2017.
[CrossRef] [Google Scholar] [Publisher Link]

[6] Adrien M. Bizeray et al., “Identifiability and Parameter Estimation of the Single Particle Lithium-Ion Battery Model,” IEEE Transactions on Control Systems Technology, vol. 27, no. 5, pp. 1862-1877, 2019.
[CrossRef] [Google Scholar] [Publisher Link]

[7] Rocco Morello et al., “Advances in Li-Ion Battery Management for Electric Vehicles,” IECON 2018 - 44^th Annual Conference of the IEEE Industrial Electronics Society, Washington, DC, USA, pp. 4949-4955, 2018.
[CrossRef] [Google Scholar] [Publisher Link]

[8] Xiangkun Wu et al., “Safety Issues in Lithium Ion Batteries: Materials and Cell Design,” Frontiers in Energy Research, vol. 7, pp. 1-17, 2019.
[CrossRef] [Google Scholar] [Publisher Link]

[9] Saeid Nahavandi, “Industry 5.0-A Human-Centric Solution,” Sustainability, vol. 11, no. 16, pp. 1-13, 2019.
[CrossRef] [Google Scholar] [Publisher Link]

[10] Roeland Bisschop, Ola Willstrand, and Max Rosengren, “Handling Lithium-Ion Batteries in Electric Vehicles: Preventing and Recovering from Hazardous Events,” Fire Technology, vol. 56, no. 6, pp. 2671-2694, 2020.
[CrossRef] [Google Scholar] [Publisher Link]

[11] Jian Duan et al., “Building Safe Lithium-Ion Batteries for Electric Vehicles: A Review,”              Electrochemical Energy Reviews, vol. 3, no. 1, pp. 1-42, 2020.
[CrossRef] [Google Scholar] [Publisher Link]

[12] Maija Breque, Lars De Nul, and Athanasios Petridis, “Industry 5.0: Towards a Sustainable, Human-Centric and Resilient European Industry,” Directorate General for Research and Innovation (DG RTD) of the European Commission, 2021.
[Google Scholar]

[13] Mengchao Yi et al., “Ultrasonic Tomography Study of Metal Defect Detection in Lithium-Ion Battery,” Frontiers in Energy Research, vol. 9, pp. 1-15, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[14] Muthukrishnan Kaliaperumal et al., “Cause and Mitigation of Lithium-Ion Battery Failure-A Review,” Materials, vol. 14, no. 19, pp. 1-38, 2021.
[CrossRef] [Google Scholar] [Publisher Link]              

[15] H.J. Xie et al., “Lithium-Ion Battery Thermal Runaway Electro-Thermal Triggering Method and Toxicity Analysis,” IOP Conference Series: Earth and Environmental Science, vol. 701, no. 1, pp. 1-16, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[16] Suriyan Anandavel et al., “Application of Digital Twins to the Product Lifecycle Management of Battery Packs of Electric Vehicles,” IET Collaborative Intelligent Manufacturing, vol. 3, no. 4, pp. 356-366, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[17] Yuqing Chen et al., “A Review of Lithium-Ion Battery Safety Concerns: The Issues, Strategies, and Testing Standards,” Journal of Energy Chemistry, vol. 59, pp. 83-99, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[18] Bloomberg NEF, 2H 2023 Energy Storage Market Outlook, 2023. [Online]. Available: https://about.bnef.com/insights/clean-energy/2h-2023-energy-storage-market-outlook/

[19] International Energy Agency (IEA), Global EV Outlook 2023, Paris, France: IEA, 2023. [Online]. Available: https://www.iea.org/reports/global-ev-outlook-2023

[20] In-Taek Oh et al., “Li-Ion Battery Immersed Heat Pipe Cooling Technology for Electric Vehicles,” Electronics, vol. 12, no. 24, pp. 1-28, 2023.
[CrossRef] [Google Scholar] [Publisher Link]

[21] Amit Kumar Tyagi, and Richa Richa, “Smart Manufacturing using Internet of Things, Artificial Intelligence, and Digital Twin Technology,” Global Perspectives on Robotics and Autonomous Systems: Development and Applications. Hershey, PA, USA: IGI Global, 2023.
[CrossRef] [Google Scholar] [Publisher Link]

[22] Aslihan Örüm Aydin et al., “Lithium-Ion Battery Manufacturing: Industrial View on Processing Challenges, Possible Solutions and Recent Advances,” Batteries, vol. 9, no. 11, pp. 1-29, 2023.
[CrossRef] [Google Scholar] [Publisher Link]

[23] Joel Alves, Tânia M. Lima, and Pedro D. Gaspar, “Is Industry 5.0 a Human-Centered Approach? A Systematic Review,” Processes, vol. 11, no. 1, pp. 1-15, 2023.
[CrossRef] [Google Scholar] [Publisher Link]

[24] Fabian Konwitschny et al., “Design and Implementation of a Flexible Prototype Assembly System for Lithium-Metal-based All-Solid-State Batteries,” Production & Manufacturing Research, vol. 12, no. 1, pp. 1-25, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[25] Sahithi Maddipatla, Lingxi Kong, and Michael Pecht, “Safety Analysis of Lithium-Ion Cylindrical Batteries using Design and Process Failure Mode and Effect Analysis,” Batteries, vol. 10, no. 3, pp. 1-29, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[26] In Taek Song et al., “Thermal Runaway Prevention through Scalable Fabrication of Safety Reinforced Layer in Practical Li-Ion Batteries,” Nature Communications, vol. 15, no. 1, pp. 1-11, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[27] Yuan Yuan et al., “Influence of Cathode Materials on Thermal Characteristics of Lithium-Ion Batteries,” Frontiers in Chemistry, vol. 12, pp. 1-10, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[28] Shyba Zaheer et al., “Design and Implementation of a Real-Time Health Monitoring System for Lithium-Ion Batteries,” Journal of Electrical Systems, vol. 20, no. 10s, pp. 6078-6086, 2024.
[Publisher Link]

[29] Ahmed Awouda et al., “IoT-based Framework for Digital Twins in the Industry 5.0 Era,” Sensors, vol. 24, no. 2, pp. 1-27, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[30] Vibhor Mishra et al., “Lithium-Ion Battery Safety: Hazards, Mechanisms, and Mitigation Strategies,” International Conference Recent Advances in Materials, Processes and Technology for Sustainability (RAMPTS), Atlantis Press, pp. 389-405, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[31] Ziyu Wang et al., “Accidents Involving Lithium-Ion Batteries in Non-Application Stages: Incident Characteristics, Environmental Impacts, and Response Strategies,” BMC Chemistry, vol. 19, no. 1, pp. 1-13, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[32] Jinkun Dai, and Jihong Pan, “A Risk Analysis Method for Potential Failure Modes in the Lithium-Ion Battery Assembly Process based on Optimized FMEA and DHHFLTS,” Scientific Reports, vol. 15, no. 1, pp. 1-25, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[33] Jingyu Zhao et al., “Thermal Runaway Critical Threshold and Gas Release Safety Boundary of 18,650 Lithium-Ion Battery in State of Charge,” Processes, vol. 13, no. 7, pp. 1-21, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[34] Telecommunication Engineering Centre, Department of Telecommunications, Government of India, Industry 4.0: The Future of Smart Manufacturing, Technical Report TEC 31238:2025, Release 1.0, 2025. [Online]. Available: https://www.tec.gov.in/pdf/TR/TR_Industry%204.0%20The%20Future%20of%20Smart%20Manufacturing.pdf

[35] Lei Yao et al., “A Comprehensive Review of Li-Ion Battery Safety Issues and Fault Diagnosis Strategies throughout the Entire Lifecycle,” Journal of Energy Storage, vol. 136, 2025.
[CrossRef] [Google Scholar] [Publisher Link]