Identifying and preventing human error in the sugar production process: A multi-stage approach using HTA, HEC and PHEA techniques

Abstract

This article discusses the importance of identifying and preventing human error in industrial environments, specifically in the sugar production process. The article emphasizes the importance of choosing the right technique for risk assessment studies resulting from human errors. A cross-sectional study was conducted using a multi-stage approach – Hierarchical Task Analysis (HTA), Human Error Calculator (HEC), and Predictive Human Error Analysis (PHEA) – to identify potential human errors in the sugar production process. The HTA, HEC, and PHEA techniques were employed to evaluate each stage of the process for potential human errors. The results of the HTA technique identified 35 tasks and 83 sub-tasks in 14 units of the sugar production process. According to HEC technique 4 tasks with 80 % probability of human error and 2 tasks with 50 % probability of human error had the highest calculated error probabilities. The factors of individual skill, task repetition and importance were the most important factors of human error in the present study. The analysis of PHEA worksheets showed that the number of human errors identified in the tasks with highest probability were 8 errors, of which 50 % were action errors, 25 % checking errors, 13 % selection errors, and 12 % retrieval errors. To mitigate the consequences of human error, it was recommended training courses, raising operator awareness of error consequences, and installing instructions in the sugar production process. Based on the findings, the article concludes that the HEC and PHEA techniques are applicable and effective in identifying and analyzing human errors in process and food industries.