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Classification and Quantification of Human Error in Manufacturing: A Case Study in Complex Manual Assembly

Torres, Yaniel ; Nadeau, Sylvie ; Landau, Kurt (2022):
Classification and Quantification of Human Error in Manufacturing: A Case Study in Complex Manual Assembly. (Publisher's Version)
In: Applied Sciences, 11 (2), MDPI, e-ISSN 2076-3417,
DOI: 10.26083/tuprints-00017794,
[Article]

Abstract

Manual assembly operations are sensitive to human errors that can diminish the quality of final products. The paper shows an application of human reliability analysis in a realistic manufacturing context to identify where and why manual assembly errors occur. The techniques SHERPA and HEART were used to perform the analysis of human reliability. Three critical tasks were selected for analysis based on quality records: (1) installation of three types of brackets using fasteners, (2) fixation of a data cable to the assembly structure using cushioned loop clamps and (3) installation of cap covers to protect inlets. The identified error modes with SHERPA were: 36 action errors, nine selection errors, eight information retrieval errors and six checking errors. According to HEART, the highest human error probabilities were associated with assembly parts sensitive to geometry-related errors (brackets and cushioned loop clamps). The study showed that perceptually engaging assembly instructions seem to offer the highest potential for error reduction and performance improvement. Other identified areas of action were the improvement of the inspection process and workers’ provision with better tracking and better feedback. Implementation of assembly guidance systems could potentially benefit worker’s performance and decrease assembly errors.

Item Type: Article
Erschienen: 2022
Creators: Torres, Yaniel ; Nadeau, Sylvie ; Landau, Kurt
Origin: Secondary publication
Status: Publisher's Version
Title: Classification and Quantification of Human Error in Manufacturing: A Case Study in Complex Manual Assembly
Language: English
Abstract:

Manual assembly operations are sensitive to human errors that can diminish the quality of final products. The paper shows an application of human reliability analysis in a realistic manufacturing context to identify where and why manual assembly errors occur. The techniques SHERPA and HEART were used to perform the analysis of human reliability. Three critical tasks were selected for analysis based on quality records: (1) installation of three types of brackets using fasteners, (2) fixation of a data cable to the assembly structure using cushioned loop clamps and (3) installation of cap covers to protect inlets. The identified error modes with SHERPA were: 36 action errors, nine selection errors, eight information retrieval errors and six checking errors. According to HEART, the highest human error probabilities were associated with assembly parts sensitive to geometry-related errors (brackets and cushioned loop clamps). The study showed that perceptually engaging assembly instructions seem to offer the highest potential for error reduction and performance improvement. Other identified areas of action were the improvement of the inspection process and workers’ provision with better tracking and better feedback. Implementation of assembly guidance systems could potentially benefit worker’s performance and decrease assembly errors.

Journal or Publication Title: Applied Sciences
Journal Volume: 11
Issue Number: 2
Publisher: MDPI
Collation: 24 Seiten
Uncontrolled Keywords: human reliability analysis, manual assembly, human error, quality, ergonomics
Divisions: 16 Department of Mechanical Engineering
16 Department of Mechanical Engineering > Ergonomics (IAD)
Date Deposited: 04 Feb 2022 14:34
DOI: 10.26083/tuprints-00017794
URL / URN: https://tuprints.ulb.tu-darmstadt.de/17794
URN: urn:nbn:de:tuda-tuprints-177948
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