Windy Wijayanti Windy, Harmein Nasution, Listiani Nurul Huda

The Role of Human Error in Production Process Failures: A Systematic Literature Review

Introduction

The role of human error in production process failures: a systematic literature review. Systematic review on human error's role in production failures. Discover how poor training, environment, & SOPs cause defects, impacting quality, safety, & costs. Explores methods like CREAM, SHERPA, HEART, FMEA.

Abstract

Human error One of the most common causes of production failures is human mistake, which can impact product quality, operational efficiency, and workplace safety. This research aims to analyze the role of human error in the production process using various analytical methods found in the literature. This research uses a Systematic Literature Review (SLR) approach to explore the literature related to Human Error in the production process, with the aim of identifying, evaluating, and synthesizing the results of relevant studies. This research shows that 70-90% of quality defects are caused by human error, which impacts quality, increases operational costs, and poses a risk of workplace accidents. Research shows that factors such as lack of training, misunderstanding, as well as an unergonomic work environment, stress, and unclear or complicated SOPs also increase the risk of human error. The use of methods such as CREAM (Cognitive Reliability and Error Analysis Method) is employed to evaluate human reliability and predict Human Error Probability (HEP) in complex cognitive tasks. SHERPA is a method used to identify, predict, and reduce the potential for human error in a system. HEART (Human Error Assessment and Reduction Technique) is a technique designed to estimate the likelihood of human error based on specific working conditions. FMEA (Failure Modes and Effects Analysis) is a systematic method used to identify and analyze potential failures in a process or system.

Review

This systematic literature review addresses the critical and highly relevant topic of human error in production process failures. Given that human error is widely acknowledged as a significant contributor to operational inefficiencies, quality defects, and safety incidents, a comprehensive synthesis of existing knowledge is particularly valuable. The authors aim to analyze the multifaceted role of human error by employing a rigorous Systematic Literature Review (SLR) approach. This methodology is appropriate for identifying, evaluating, and synthesizing findings from a broad range of studies, promising a structured overview of the current understanding in this domain. The review's preliminary findings, as outlined in the abstract, highlight the pervasive impact of human error, attributing a substantial 70-90% of quality defects to this factor. This directly translates to increased operational costs and heightened risks of workplace accidents, underscoring the severity of the problem. Crucially, the abstract identifies several contributing factors, including inadequate training, misunderstandings, unergonomic work environments, stress, and poorly defined standard operating procedures. The strength of this review also lies in its identification of various analytical methods used to assess and mitigate human error, such as CREAM for predicting Human Error Probability, SHERPA for error identification and reduction, HEART for likelihood estimation, and FMEA for systematic failure analysis. This comprehensive overview of methods provides valuable resources for practitioners and researchers alike. Overall, this SLR appears to offer a valuable contribution to the field by consolidating existing knowledge on human error in production processes. The identification of both prevalent issues and a suite of analytical tools is particularly useful for both academic discourse and practical application. While the abstract provides a strong overview, a deeper discussion in the full paper on the comparative strengths, weaknesses, and applicability contexts of the identified analytical methods (CREAM, SHERPA, HEART, FMEA) would further enhance its utility. Moreover, exploring potential gaps in the existing literature or emerging trends in human error prevention could provide fruitful avenues for future research. This review serves as an excellent foundational text for anyone seeking to understand and address human error within complex industrial settings.

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