The course explores the psychology and mechanisms of human errors. Upon completion of the course, participants shall acquire the ability to identify key drivers and root cause of human errors at workplace. With the aim of improving productivity at manufacturing sites, participants shall be able to take necessary preventive measures (on-site improvement, etc.) to reduce or prevent errors.

Objectives:

• Understand the psychology of human error
• Human error classification into commission and omission errors.
• Maintain a resilient system to maintain effective performance to deliver a quality product even if mistake is made.
• Effective human performance tools to support effective deviation investigation and design effective corrective and preventive action.

Course Outline:

The course covers tutorial, discussions and/or facilitated activities.

Day 1

Module 1 – Introduction to Human Error

• Human errors and its impact
• Accident causation theories
  • Murphy’s law
  • Heinrich theory of accident
  • James Reasons cheese mode
• Case study

Module 2 – Understanding on Human Error

• Human Error Classification
• Rasmussen’s SRK (Skill, Rule and Knowledge) Model
• Conscious and automatic behavior
• Psychology of human errors
• Workshop

Module 3 – Identify Factors of Human Error

• Introduction of verbal data analysis tool
• Accident causation theories
  • Affinity diagram
  • Relationship diagram
  • Matrix diagram
  • Activity network diagram
• Classification of human error into 6M
• Cause and Effect diagram
• Workshop

Day 2

Module 4 – Human Error Investigation Technique

• Process flow and timeline analysis
• Data collection tools
  • Checksheet
  • Graph
  • Stratification
  • Pareto Diagram
• Fact findings through interview
  • Do and don’t in interview
  • Planning and conducting the interview
• Root cause analysis method
  • Fault Tree Analysis (FTA)
  • 5-Why analysis
• Workshop

Module 5 – Human Error Prevention Methodology

• Strategies for reducing human error in workspace
  • Identify main drivers for human error
  • Methodologies to minimise risk of human error (prevent, reduce, detect)
    • 5S 3T, Poka Yoke, Kaizen
  • Eliminate or simplify complex task
  • Visual aids, checklists stratification, pitfalls of multiple checks
  • Roles and responsibilities
  • Periodical audits
  • Organizational knowledge
  • Training methodology
  • Culture of escalation
  • Horizontal development

Who Should Attend This Course?

Managers, Engineers, Officers, Supervisors who manage production processes and aim to enhance product quality and process productivity through reducing or preventing human errors in production.

Methodology:

• Question & answer / Workshop

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