Human errors significantly hamper business operations. While many may acknowledge the concept of "human errors," fewer possess a comprehensive grasp of its various categories and underlying factors. Neglecting to address issues promptly can lead to irreversible consequences.

This article provides an overview of human error and the characteristics of people who are prone to it, as well as the factors that cause it and countermeasures. We will also introduce systems that are effective in preventing human error, so please refer to this article if you are wondering what kind of measures to take.

Human Error: The definition

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Human errors are essentially errors committed by human workers. Human errors are solely attributed to the negligence of on-site workers, distinct from system defects and insufficient instruction manuals. Nevertheless, the primary causes of the stated issues may be attributed to human errors.

Unlike machines, it is impossible for human beings to perform their work perfectly every time. Furthermore, a variety of factors may contribute to the occurrence of human errors. Even a small mistake can result in the significant loss of public trust and should not be underestimated. To prevent human errors, it is important to assume all possible human risks and take countermeasures in advance.

Categories of Human Errors

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There are two main categories of human errors: intentional and negligent.

Errors resulting from intentional actions are called intentional type. The cause of this type of error could be due to the worker’s negligence with intentional corner cutting or careless practices.

On the other hand, negligent type refers to unintentional errors. Human error, such as misidentification or carelessness, may lead to such problems regardless of their intent.

In the following chapters, further details about each type will be provided.

Characteristics of People Prone to Human Errors

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Characteristics of people who are prone to making mistakes are as follows.

• Lacks knowledge
• Lacks discretion
• Poor communication skills
• Passive
• Subjective
• Poor stress managing

Working accurately requires a solid understanding of the material. Neglecting details may lead to unforeseen errors.

Since errors often occur when one makes an individual decision, effective communication is vital to minimize errors. Workers who fail to take initiative often lack responsibility and individuality which may make them prone to errors.

If one fails to view themselves objectively, they may make poor decisions stemming from their poor health and lack of strength. In addition, excessive stress can exacerbate irritability, anxiety and trigger new issues.

Despite these traits, human errors may occur to any worker so we must always stay cautious.

Five Causes of Human Errors

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According to the SHELL model, human error consists of the following five factors.

Factors	Overview
Manuals/Rules (Software)	Fundamental rules and systems for training employees
Settings and Machinery (Hardware)	Equipment, machinery, and other objects to be operated
Working Environment	External environment, including air conditioning, lighting, noise control, as well as the atmosphere of the work site
Person (Liveware)	The physical and mental state of the parties involved in the work.
Surrounding workers (Liveware)	The parties involved in the work and all those involved on site.

The SHELL model is a structured model of human error factors, proposed by Frank H. Hawkins, a captain at KLM Netherlands Airport. SHELL was named after the initial letters of the five factors above.

This model assumes that human errors are inevitable and places human resources at the core of its theory. The model explains why human errors occur by comparing the relationships among the five factors.

Main Causes of Human Error in Manufacturing Sites

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Let’s consider the causes of human errors that commonly occur in the manufacturing industry, by dividing them into the following two categories.

• Causes of intentional human errors
• Causes of unintentional human errors

The characteristics of each cause are described below.

Causes of Human Error Caused by Intentional Human Error

The main causes of intentional human errors are thought to be carelessness and underestimation of risks. These are problems that surface as human errors due to the operator's negligence.

Let's look at the concreate causes of each error.

Laziness

A representative example of the cause of intentional human error is the complacent attitude and consciousness of workers. Even the slightest laziness to make the work process a little easier, may trigger countless problems. Human errors caused by complacency is said to be a common mistake for either a veteran employee or by those who have just started getting used to the work.

Underestimation of Risk

Underestimation of risk is, simply put, an error in judgment. In many cases, human error occurs because of negligence. In these cases, the importance of checking, reporting, communicating, and consulting is usually considered insignificant.

Causes of Unintentional Human Errors

The following nine examples are causes of unintentional human errors.

• Forgetfulness
• Insufficient confirmation
• Misperception
• Fatigue
• Workload
• Assumptions
• Lack of coordination
• Poor work environment
• Insufficient knowledge and underexperienced workers

Let's consider the reasons and background for each cause.

Forgetfulness

It is not a rare case for a worker to accidentally forget some important processes. Even if the workers carefully process the work, memory may fade, causing the workers to forget unwritten rules.

Insufficient confirmation

Endless instances exist where people overlook serious errors or misunderstand the situation. Although the cause is similar laziness, human errors caused by insufficient confirmation is difficult to counteract as it is not intentional.

Misconception

Misrecognition of rules and work contents may result in unintentional mistakes. Administrators must be careful not to give ambiguous instructions, in order to prevent misconceptions.

Fatigue

When workers are excessively fatigued, they will underperform. Drowsiness can prevent the body from working as it should, and concentration and alertness can be distracted. It is not rare for fatigue to accumulate without the worker’s awareness.

Workload

In some cases, the work contents may be too complicated, placing an excessive burden on the workers and inducing human errors. In addition, a series of simple tasks that require a large amount of process and time can also lead to diverted attention and concentration.

Assumptions

When preconceptions and stereotypes are strong, it is easy for errors to occur due to assumptions. Human errors tend to occur more frequently under unusual conditions, so care must be taken.

Lack of coordination

It is difficult to avoid human error when there is insufficient coordination in the field. The fundamental problem cannot be resolved unless the deficiencies in the information sharing system are resolved.

Poor working environment.

Poorly maintained air conditioning and lighting, as well as inadequate maintenance of equipment, are also factors that contribute to human errors. Mistakes and problems are bound to occur in a site with poor working environment and low safety standards. The work site's atmosphere and corporate culture may also lead to group defects, contributing to a poor work environment.

Insufficient knowledge and underexperienced workers

Inexperienced new workers often commit human errors due to the lack of knowledge and insufficient training. Despite their experience, veteran workers may also cause errors as they struggle to adapt to new rules and procedures. Human error can also stem from overconfidence in one's abilities. Furthermore, human errors may occur due to the arrogance of thinking,” I can do this because I have experience.”

Examples of Human Error

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Human error can cause many accidents in the workplace and its effects can be felt throughout an organization. A specific case in point is human error in the airline industry. For example, the 1977 aircraft crash at Tenerife Airport, which resulted in 583 fatalities, was caused by misjudgment and improper communication by the captain. This accident clearly illustrates how errors can have serious consequences.

In a work environment, basic negligence, such as inadvertent errors or failure to check, is a key factor in preventing serious accidents. The context in which cognitive errors and errors in judgment occur often includes poor communication and excessive workload in the workplace. These can be improved with external assistance and the introduction of systems.

Defective products may also be produced at manufacturing sites due to the use of incorrect parts or omission of procedures. These errors can be prevented with proper education and training, as well as enhanced verification processes. To prevent human error, organizations must create a work environment that provides clear instructions and support to employees.

Measures to prevent human error in manufacturing.

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Human errors that occur in the manufacturing industry may be prevented by taking the following measures.

• Implementing risk prediction activities.
• Active communication.
• Improving the work environment.
• Strengthening education.
• Make a habit to check.
• Creating a manual.

Let’s check the points and precautions for each preventive measure.

Implementing risk prediction activities. The frequency of human errors differs greatly depending on whether the potential risks are known in advance or not. By conducting risk prediction training (KYT) daily, such as through group discussions and the posting of posters and signs, human errors may be minimized.

Activate communication.

Many unintentional human errors stem from a lack of communication. Therefore, revitalizing communication shall improve the work environment. In addition to reviewing the communication system, it is important to create an atmosphere in which it is easy to ask for advice.

Improving the work environment

Creating an environment that makes it easy to concentrate on work will reduce inadvertent human error. Working in a poor environment can have a negative impact on the physical condition of employees. In addition to improving the layout of the work site, ensure comfortable room temperature, noise control, and safety measures.

Reinforce education.

Enhance employee education by holding regular training sessions and workshops to increase risk literacy at the site. Remind them of the importance of awareness and safety checks when performing work to prevent human error. However, excessive pressure is counterproductive. It is important to provide appropriate training according to the characteristics of each worker.

Making it a habit to check

To reduce human error, it is essential to review the checking process. In addition to making, it a habit for each employee to check, strengthening the checking system for the entire team will reduce the occurrence of human errors by individuals.

Create manuals.

Creating manuals is essential to ensure that all employees understand processes that are complicated and difficult to understand. A well-developed manual will help avoid arbitrary errors in judgment. When creating the manual, be sure to incorporate the opinions of the field to make it understandable for everyone.

Systems that can be used for human error countermeasures in the manufacturing industry

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Human error in the manufacturing industry can also be counteracted by automating the inspection process using specialized tools.

In this chapter, we pick up two recommended products from among Ricoh's on-site support systems.

• RICOH SC-10A
• RICOH SC-20

The following is an overview of each of these products and the key points that make them stand out.

RICOH SC-10A

The RICOH SC-10A is a camera system with a high-magnification lens that is specialized for on-site work support. By automatically recognizing work processes with images, it prevents inattention and misrecognition caused by visual inspection.

The system is an all-in-one system with all the functions necessary for checking and is easy to set up. Information can be shared in real time, making human error countermeasures easy.

RICOH SC-20

The RICOH SC-20 is a camera that monitors errors in manual work processes. It is characterized by its ability to perform quality checks in real time, while simultaneously performing inspections, and all processes necessary for verification can be automated.

Up to 20 checkpoints can be set, and a batch inspection after the work is completed is also possible. The low cost and ease of use of this system, which does not require a PC, has made it a popular choice for a wide range of workplaces.

Conclusion

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If human hands are involved in work, it is impossible to eliminate all human errors. However, it is possible to minimize the frequency of human error by recognizing that people make mistakes and making efforts to minimize the frequency of human error. Prevent human error by preparing the work environment, encouraging employees to take appropriate actions, and effectively incorporating countermeasure tools.

If you have any questions about human error countermeasures on production lines in the manufacturing industry, please contact Ricoh. In addition to introducing our recommended products, we also provide quotes and free trials, so why not take this opportunity to consider our services?

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