Human Factors - Real World Operational Cost savings


		AcuSafe -> October 1999 Newsletter
		Human Factors - Real World Operational Cost Savings

Those in attendance at the September 1999 American Petroleum Institute Fire and Safety Conference in Tulsa were treated to an extensive paper on real world case studies on the effectiveness on Human Factors Engineering (HFE). Larry Csengery of Equilon shared some of the basics of HFE and then some actual examples of how easily some recurring problems had been solved using human factors focus. The operational savings obtained for relatively low cost was impressive.

Basic Human Factors

The paper started with an excellent abbreviated course in human factor engineering. Background included topics such as Information Overload, Schematic Layout, Alarm Management. Csengery then covered the science of effective procedure writing and layout. Larry espouses a simple columnar format, using numbers and checkmarks. Action verbs leading the statement and successful feedback indicators are important as well.

Real World problem Solving

The best parts of Larry’s presentation were specific examples of his experiences in a small European batch chemical plant. They had been plagued with many near misses and poor productivity in meeting product specifications.

Nine separate, small incidents were investigated for Human Factor contributions. What was significant was that most incidents could have been predicted using Human Reliability Analysis techniques.

Larry’s team found that most problems happened to less experienced operators. The “little tricks” necessary in batch operations were not documented. Instead, the procedures were long dissertations with as many as 10 action steps in a paragraph – consequently, no one used them.

Simple labeling issues often appeared to be the root cause. Larry amused the crowd by explaining an operator’s use of a 0 -100 psi gauge as a vacuum indicator: when the pointer was on the “T” of Taylor, the operator deemed the vacuum “right.”

Human Error is Overused

Most of the incidents had occurred repeatedly, and they had been attributed to “Human Error,” a term Csengery believes is too easy to use – and thus overused. His study suggests that 70 percent of incidents are due to “Human Error” and 80 percent of “Human Error” incidents are preventable. Good engineering and audit techniques can lead to simple solutions that prevent the errors before they can occur.

Csengery pointed out that his work at this particular plant had a very rapid payout in reduced losses, fewer product-specification reblends, and improved productivity. Few of the proposed solutions had significant cost associated with them. It was simply labels, procedures, control layout, and environmental conditions.

Larry Csengery has over 30 years with Shell and Equilon and is located in Equilon’s Houston Technical Center.