Petrochemical industry is one of the most accident prone industries, and most accidents in this industry are related to human factors. The principles of Lean production are one of the approaches used to improve the production situation. Various studies have shown that implementing Lean production improves the safety and ergonomics. In this study, the principles of Lean production were used to reduce human error and improve response in emergencies.
The basic CREAM method was used to evaluate human errors. In order to select Lean production tools appropriate to the emergency response tasks, the opinions of the 20-member panel of specialists and experts, including industry managers, HSE officials, and university professors, were used. For examining the impact of Lean production principles on reducing human error in emergencies, 6 months after the implementation of Lean production interventions, human error was re-examined. Evaluation of human errors after Lean production interventions was also performed by basic CREAM method.
Row | Conditions affecting a person's performance | Description of items / limits (level) | Expected effect on performance reliability |
1 | Organizational capability | Very efficient / efficient / inefficient | Improve / ineffective / reduce |
2 | work conditions | Excellent / proportionate / disproportionate | Improve / ineffective / reduce |
3 | Proportionality of human-machine systems and effective operational support | Excellent / Adequate / Tolerable / Inadequate | Improve / Ineffective / Ineffective / Decrease |
4 | Access to methods and programs | Suitable / tolerable / inappropriate | Improve / ineffective / reduce |
5 | Do two or more things at the same time | Less than individual power / proportional to individual power / more than individual power | Improve / ineffective / reduce |
6 | Time available to get the job done | Enough / Temporarily inadequate / | Improve / ineffective / reduce |
7 | Work time (circadian rhythm) | Regular work shifts / irregular work shifts | Ineffective / reduced |
8 | Quality of training and work experience | Adequate (highly experienced) / Adequate (limited experience) / Insufficient | Improve / ineffective / reduce |
9 | Collaboration and interaction between partners | Excellent / good / poor / no cooperation | Improve / Ineffective / Ineffective / Decrease |
The results of the evaluation of human errors before and after the implementation of Lean production interventions showed that the level of control mode of the three sub-tasks improved from the tactical control mode to the strategic control mode. The most probable human error was in evacuate sub-task.
Sub-duties | Description |
1 | Detection of fire or leakage in the unit, automatic notification and extinguishing and use of equipment at the scene to control |
2 | Contact the fire station to report the accident, severity and location |
3 | Manual isolation to control the accident |
4 | Communication with the head of the unit, the intelligence officer and the guard on duty to send troops to the scene |
5 | Operations and operations control such as isolation, controlling firefighting operations |
6 | Firefighting by the fire brigade |
7 | Transporting the injured to the clinic for treatment |
8 | Statistics to completely evacuate people from the scene |
9 | Carrying out relief and treatment operations on the injured and sending the injured to a clinic or hospital |
10 | Perform repairs after firefighting in the unit |
Sub-duties | IƩ | RƩ | β | CFPt | Control style | Control style |
1 | 3 | 0 | 3- | 0.00099 | Tactical control | Strategic control |
2 | 3 | 0 | 3- | 0.00099 | Tactical control | Tactical control |
3 | 0 | 0 | 0 | 0.0056 | Tactical control | Tactical control |
4 | 1 | 0 | 1- | 0.0031 | Tactical control | Tactical control |
5 | 0 | 0 | 0 | 0.0056 | Tactical control | Tactical control |
6 | 7 | 0 | 7- | 0.000099 | Strategic control | Strategic control |
7 | 1 | 2 | 1 | 0.0099 | Tactical control | Tactical control |
8 | 0 | 2 | 2 | 0.0177 | Tactical control | Strategic control |
9 | 3 | 0 | 3- | 0.00099 | Tactical control | Strategic control |
10 | 1 | 1 | 0 | 0.0056 | Tactical control | Tactical control |
Sub-duties | IƩ | RƩ | β | CFPt | Control style |
1 | 4 | 0 | -4 | 0.00056 | Strategic control |
2 | 4 | 0 | -3 | 0.00056 | Tactical control |
3 | 2 | 0 | -2 | 0.00177 | Tactical control |
4 | 1 | 0 | -1 | 0.0031 | Tactical control |
5 | 3 | 0 | -3 | 0.00099 | Tactical control |
6 | 7 | 0 | -7 | 0.000099 | Strategic control |
7 | 4 | 2 | -2 | 0.00177 | Tactical control |
8 | 4 | 0 | -4 | 0.00056 | Strategic control |
9 | 4 | 0 | -4 | 0.00056 | Strategic control |
10 | 4 | 1 | -3 | 0.00099 | Tactical control |
The results of this study showed that the implementation of lean manufacturing principles in the studied industry, in most tasks, reduced the likelihood of human error. The predominant level of control in most of the tasks under study was tactical control. Considering that emergencies are one of the most important and threatening challenges in industries and the occurrence of the slightest human error in these conditions has irreversible effects on industries [20] reducing the likelihood of human error in emergency response tasks and sub-tasks is very important [4].
Considering that no study has been done on the effect of lean production on human error and one of the main objectives of this system is to improve working conditions, the study of the effect of lean production on labor and safety and ergonomics in different studies shows two views. The first view believes that lean production has positive effects on the labor force, which can be referred to the effects of lean production on job enrichment and increased employee participation [21]. Considering that the application of safety and ergonomic principles in work environments improves productivity, improves product quality, as well as increases the efficiency of individuals by optimizing tasks and work environment [22]; according to Hendrick, the principles of lean manufacturing also increase productivity, reduce human injuries and absenteeism [23].
Another view that has been pointed out by many researchers and is also very popular is that lean production increases the speed of production and the worker loses his freedom of action [28]. A study by Yang et al. showed that some lean manufacturing methods focus only on the technical aspects and pay less attention to manpower, which violates the principles of ergonomics in industry.
Statistics show that a large proportion of accidents in the workplace occur due to human error [40]. These events have many economic, social, and environmental effects on society.
Considering that reducing human errors reduces waste in the system and is in line with the goals of the lean production system, but so far no studies have been conducted on the effect of implementing lean production principles on human errors. Also, contradictory results regarding the application of lean manufacturing principles on safety and ergonomic principles have been reported in various studies.
The results of this study showed that the implementation of those interventions that in addition to improving the level of safety, can improve organizational productivity, is more accepted by industry management.
The authors of the article are grateful to the Vice Chancellor for Research and Technology of Hamadan University of Medical Sciences and the management of the petrochemical industry for their cooperation in conducting this study.
The authors declared no conflict of interest.
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