Identification and assessment of human error in Banbury Unit of the rubber industry using SHERPA Technique in 2015

With complication industrial processes and increase the probability of human error, it seems necessary to Identify, Prediction human error and offering appropriate control approach in order to eliminate and reduce or prevent errors and adverse consequences. This study was carried out to identify human errors in a rubber industry, using SHERPA technique. Unit study was selected from the 36 units based on the Critical and sensitivity of the system, then Banbury unit was selected. Job analysis and task descriptions were determined by using hierarchical task analysis (HTA) with the Prediction of the managers, transfer supervisors and experienced operators. In this study, totally 44 errors were predicted for the 4 task soot operator, mixers A operator, mixers B operator and repairman Banbury unit according to the task description and SHERPA checklist. Results showed that maximum frequency percentage error related to functional errors (63.38%) and minimum frequency percentage errors related to recovery error (85.6%) respectively. As well as assessing the identified errors risk level by risk assessment matrix method showed that 45.45% of the identified errors are unacceptable risk and 63.38 percent are unfavorable risks. As mentioned, the most significant errors that occur in Banbury Unit is related to the functional and inspectional error. Therefore, it is priority corrective actions, staff training and careful monitoring of operators’ performance and take appropriate action in detection a failure in the unit.