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Most of the industrial accidents and incidents are attributed to human errors. Many studies on industrial safety have proposed theories and solutions to mitigate human errors by improving the design and environmental aspects of the organizations. However, human error also needs to be studied from the point of view of cognitive mechanisms of workers and operators in critical industrial environment. In this regard this paper discusses exploratory study of human error in a polymer company in Mysore city. The literature review showed that human operators are always at the sharp end of the system and are prone to errors, which leads to accidents and incidents. Human fallibility is unavoidable. The primary data was collected through informal interview method involving shop floor supervisors and process operators. Separate interviews were conducted for supervisors and operators to assess the safety climate in the organization. Interview with the process operators revealed that the mixing, straining and milling sections of the organization are considered to be safety critical. All the three sections mentioned are highly procedure driven in carrying out the process operations and required safety precautionary measures in doing each task. A retrospective task analysis of the mixing, straining and milling sections were carried out and types of errors and causes of errors were identified. This paper also asserts the importance of taxonomic approach in identifying the human errors in industrial setups.

Human error analysis: a case study in a tyre tube polymer processing industry NEW