Application of SHERPA (Systematic Human Error Reduction and Prediction Approach) as an Alternative to Predict and Prevent Human Error in Manual Assembly

Abstract

Human reliability analysis (HRA) has been identified as a key approach to improve quality in the manufacturing sector. This paper presents the results of the application of SHERPA to a manual assembly task case in the electronic industry, i.e., the assembly of a printed circuit board. It also compares the use of SHERPA with other HRA techniques in a manufacturing context. A total of 16 subtasks were obtained from the breakdown of the task that was the object of study and 12 error modes were identified based on SHERPA taxonomy: eight action errors, two checking errors, and two selection errors. The use of SHERPA provides a useful framework for identifying human errors in manual assembly even though this technique was not specifically developed for manufacturing. The analysis of human errors in manufacturing needs to consider and integrate a vocabulary harmonized with production planning. Comparison between SHERPA and other HRA techniques shows that the focus of the analysis should be placed on error identification rather than the calculation of error probabilities. A semi-quantitative index could help to reconcile these approaches by identifying and evaluating error modes in their propensity to occur, without the need for an accurate estimation of error probabilities.