Advanced human factors Process Failure Modes and Effects analysis

Abstract

Process Failure Mode and Effects analysis (PFMEA) is a technique to identify, analyze and evaluate the potential failure modes of a production process. The purpose is to suggest control measures to reduce the risk of the production process effectively. NASA has used the PFMEA technique to analyze human processes or tasks. This type of analysis can be referred to as a "human factors process FMEA, HF-FMEA". HF-FMEA breaks down a task process into discrete steps so the actions associated with a process step can be specifically analyzed for potential failure. For each action performed, all potential human errors are identified. Each error is then evaluated to identify positive and negative contributing factors, barriers, and controls. The aim of these works is to give risk reduction measures to minimize the risk of human process. Although HF-PFMEA has achieved significant achievements in the analysis of human factors, the technique itself is still to be improved. For example, the technique has no generic method to decompose the task, and it is difficult to identify human operational errors comprehensively. This paper proposes some solutions to the shortcomings of the conventional approach. Advanced HF-PFMEA integrates several important concepts that distinguish it from conventional HF-FMEA, including: (1) suggest a method to break down task process according to the sequence and logicality of task process, (2) use hazard and operability study (HAZOP) to analyze human operational errors. The operational errors can be identified by determining guidewords and process parameters.