Human Factors
Man or manpower is often thought of as operator error. Operator error is possible but not actionable - therefore the study of operator impacts on process and product is required. Human factor analysis and design is the technical approach used to quantify the human impact on a product or process.
The Human Factor analysis proposed and used by QAI uses a multiple why approach to 3 levels. Each operator error (first level) must be driven to one of 5 second level causes and then to more detailed level 3 causes.
Eventually to assure success, the consideration of error proofing at the most elemental level possible is desired.
Level 2 Causes:
Work Station Design
- Level 3 Causes
- Bench/table height
- Organization of work tools (5S)
- Number of tools and placement
- Component positions
- Quantity
- Similarity
- Extended reach (occasional)
- Lighting
- Comfort features
- Foot rests/seat positions
- Standing work bench position
Ergonomics
- Level 3 causes
- Height and reach
- Work type
- Weight
- Lifting
- Motion
- Number of steps
- Degrees of freedom
- Work station interface
- Blind operation
- Posture
- Insertion force
- Static insertions
- Plastic deformation of end source
- Tool
- Vibration
- Tool design
Documentation and Training
- Level 3 Causes
- Illustrations on process documentation
- "A4" one page
- No documentation
- Validation of work practice
- Testing
- Demonstration
- Frequency of validation
- Training definition
- Complexity of documentation
- Labeling
- Legibility of work instructions
- Number of pages
- Understandability (5 second rule)
- Font size and type
Assists and Tool Design
- Level 3 causes
- Error proofing features
- Tool calibration
- Pallet compliance
- Correct tool
- Life of tool
- Fixture control
- Clamp pressure
- Cycle completion/interruption
- Locator/proximity life
- Measurement instrument
Cognitive/Perception
- Level 3 causes
- Audible noise
- Environment
- Temperature
- Humidity
- Sensitivity to interruption
- Repetition
- Motion
- Trance/zone inducement
- Sound quality
- Harmonics
- Vibration/cyclical noise
When looking at operator error on either an FMEA or during a problem solving activity, the value of discovering a root cause for prevention or control is indisputable. We encourage all to comment and improve this simple set of guidelines. For additional information or to look at performing the human factors study in support of either FMEA or 8D, call us at 248.280.4800 or fill out our contact form.
Need more information?
For more detailed information on this topic please email our qualified staff, contact us by phone at (248) 280-4800, or fill out a contact form.
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