Classification and Quantification of Human Error in Manufacturing: A Case Study in Complex Manual Assembly

Manual assembly operations are sensitive to human errors that can diminish the quality of final products. The paper shows an application reliability analysis in a realistic manufacturing context identify where and why manual occur. techniques SHERPA HEART were used perform reliability. Three critical tasks selected for based on records: (1) installation three types brackets using fasteners, (2) fixation data cable structure cushioned loop clamps (3) cap covers protect inlets. identified error modes with were: 36 action errors, nine selection eight information retrieval six checking errors. According HEART, highest probabilities associated parts geometry-related (brackets clamps). study showed perceptually engaging instructions seem offer potential reduction performance improvement. Other areas improvement inspection process workers’ provision better tracking feedback. Implementation guidance systems could potentially benefit worker’s decrease