Human reliability, error, and human factors in engineering maintenance : with reference to aviation and power generation

Of the billions of dollars spent on plant management and operation annually, an estimated 80% of the total amount is spent to rectify the chronic failure of systems, machines, and humans. Although information on human reliability, error, and human factors in engineering maintenance is scattered throughout journals and proceedings, no single resource covers all of these topics within a maintenance safety framework. Consulting different and diverse sources can not only make finding information laborious and time consuming, but also cause delays on the job.

Human Reliability, Error, and Human Factors in Engineering Maintenance with Reference to Aviation and Power Generation provides engineers a tool for meeting the increasing problem of human error. Drawing on a myriad of sources, the book provides quick and easy access to information that can then be immediately applied to actual problems in the field. It includes examples and their solutions to illustrate engineering safety management at work and gives readers a view of the intensity of developments in the area.

The author's clear, concise, user-friendly style breaks the information down into understandable and applicable concepts. This book not only provides up-to-date coverage of the on-going efforts in human reliability, error, and human factors in engineering maintenance, but also covers useful developments in the general areas of human factors, reliability, and error. This information can then be translated into increased maintenance safety that has a positive impact on the bottom line.

Author Notes

B.S. Dhillon received his Ph.D. in industrial engineering from the University of Windsor. He received his M.S. in mechanical engineering and B.S. in electrical and electronic engineering from the University of Wales.

Dr. Dhillon is a professor of engineering management in mechanical engineering at the University of Ottawa.

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Preface	p. xiii
Author Biography	p. xv
Chapter 1 Introduction	p. 1
1.1 Background	p. 1
1.2 History	p. 1
1.2.1 Human Factors	p. 1
1.2.2 Human Reliability and Error	p. 2
1.2.3 Engineering Maintenance	p. 2
1.3 Human Reliability, Error, and Human Factors in Engineering Maintenance-Related Facts and Figures	p. 2
1.4 Terms and Definitions	p. 4
1.5 Useful Information on Human Reliability, Error, and Human Factors in Engineering Maintenance	p. 5
1.5.1 Publications	p. 5
1.5.1.1 Books	p. 5
1.5.1.2 Technical Reports	p. 6
1.5.1.3 Conference Proceedings	p. 6
1.5.1.4 Journals	p. 7
1.5.2 Data Sources	p. 8
1.5.3 Organizations	p. 8
1.6 Scope of the Book	p. 9
1.7 Problems	p. 10
References	p. 10
Chapter 2 Basic Mathematical Concepts	p. 13
2.1 Introduction	p. 13
2.2 Boolean Algebra Laws and Probability Properties	p. 13
2.3 Useful Definitions	p. 16
2.3.1 Probability	p. 16
2.3.2 Cumulative Distribution Function Type I	p. 17
2.3.3 Probability Density Function Type I	p. 17
2.3.4 Probability Density Function Type II	p. 17
2.3.5 Cumulative Distribution Function Type II	p. 17
2.3.6 Reliability Function	p. 18
2.3.7 Hazard Rate Function	p. 18
2.3.8 Expected Value Type I	p. 18
2.3.9 Expected Value Type II	p. 18
2.3.10 Laplace Transform	p. 18
2.3.11 Laplace Transform: Final-Value Theorem	p. 19
2.4 Probability Distributions	p. 20
2.4.1 Poisson Distribution	p. 20
2.4.2 Binomial Distribution	p. 21
2.4.3 Geometric Distribution	p. 21
2.4.4 Exponential Distribution	p. 22
2.4.5 Normal Distribution	p. 23
2.4.6 Gamma Distribution	p. 23
2.4.7 Rayleigh Distribution	p. 24
2.4.8 Weibull Distribution	p. 24
2.5 Solving First-Order Differential Equations Using Laplace Transforms	p. 25
2.6 Problems	p. 26
References	p. 27
Chapter 3 Introductory Human Factors, Reliability, and Error Concepts	p. 29
3.1 Introduction	p. 29
3.2 Human Factors Objectives and Man-Machine System Types and Comparisons	p. 29
3.3 Human Sensory Capacities and Typical Human Behaviors and Their Corresponding Design Considerations	p. 31
3.3.1 Touch	p. 31
3.3.2 Sight	p. 31
3.3.3 Vibration	p. 32
3.3.4 Noise	p. 32
3.4 Human Factors-Related Formulas	p. 33
3.4.1 Formula for Estimating Inspector Performance	p. 33
3.4.2 Formula for Estimating Rest Period	p. 33
3.4.3 Formula for Estimating Character Height	p. 33
3.4.4 Formula for Estimating Glare Constant	p. 34
3.5 Useful Human Factors Guidelines and Data Collection Sources	p. 34
3.6 Human Performance Effectiveness and Operator Stress Characteristics	p. 35
3.7 Occupational Stressors and General Stress Factors	p. 36
3.8 Human Performance Reliability and Correctability Functions	p. 37
3.8.1 Human Performance Reliability Function	p. 37
3.8.2 Human Performance Correctability Function	p. 39
3.9 Human Error Occurrence Reasons, Consequences, Ways, and Classifications	p. 39
3.10 Human Reliability and Error Data Collection Sources and Quantitative Data	p. 40
3.11 Problems	p. 41
References	p. 42
Chapter 4 Methods for Performing Human Reliability and Error Analysis in Engineering Maintenance	p. 45
4.1 Introduction	p. 45
4.2 Failure Modes and Effect Analysis (FMEA)	p. 45
4.3 Man-Machine Systems Analysis	p. 47
4.4 Root Cause Analysis (RCA)	p. 47
4.5 Error-Cause Removal Program (ECRP)	p. 49
4.6 Cause-and-Effect Diagram (CAED)	p. 49
4.7 Probability Tree Method	p. 50
4.8 Fault Tree Analysis (FTA)	p. 53
4.8.1 Fault Tree Symbols	p. 53
4.8.2 Steps for Performing FTA	p. 54
4.8.3 Probability Evaluation of Fault Trees	p. 54
4.9 Markov Method	p. 57
4.10 Problems	p. 60
References	p. 60
Chapter 5 Human Error in Maintenance	p. 63
5.1 Introduction	p. 63
5.2 Facts, Figures, and Examples	p. 63
5.3 Occurrence of Maintenance Error in Equipment Life Cycle and Elements of a Maintenance Person's Time	p. 64
5.4 Maintenance Environment and Causes for the Occurrence of Maintenance Errors	p. 65
5.4.1 Noise	p. 65
5.4.2 Poor Illumination	p. 65
5.4.3 Temperature Variations	p. 65
5.5 Types of Maintenance Errors and Typical Maintenance Errors	p. 66
5.6 Common Maintainability Design Errors and Useful Design Improvement Guidelines to Reduce Equipment Maintenance Errors	p. 67
5.7 Maintenance Work Instructions	p. 68
5.8 Maintenance Error Analysis Methods	p. 69
5.8.1 Probability Tree Method	p. 69
5.8.2 Pontecorvo Method	p. 71
5.8.3 Pareto Analysis	p. 74
5.8.4 Markov Method	p. 74
5.9 Problems	p. 76
References	p. 76
Chapter 6 Human Factors in Aviation Maintenance	p. 79
6.1 Introduction	p. 79
6.2 The Need for Human Factors in Aviation Maintenance and How Human Factors Impact Aircraft Engineering and Maintenance	p. 79
6.3 Human Factors Challenges in Aviation Maintenance	p. 80
6.4 Practical Human Factors Guide for the Aviation Maintenance Environment	p. 80
6.5 Integrated Maintenance Human Factors Management System (IMMS)	p. 83
6.6 Aviation Maintenance Human Factors Training Program and Human Factors Training Areas for Aviation Maintenance Personnel	p. 84
6.7 Common Human Factors-Related Aviation Maintenance Problems	p. 86
6.8 Problems	p. 86
References	p. 87
Chapter 7 Human Factors in Power Plant Maintenance	p. 89
7.1 Introduction	p. 89
7.2 Human Factors Engineering Maintenance-Related Deficiencies in Power Plant Systems	p. 89
7.3 Desirable Human Factors Engineering Maintenance-Related Attributes of Well-Designed Systems in Power Generation	p. 90
7.4 Power Generation Plant Performance Goals That Drive Decisions about Human Factors	p. 91
7.5 Study of Human Factors in Power Plants	p. 92
7.6 Human Factors Approaches for Assessing and Improving Power Plant Maintainability	p. 93
7.6.1 Task Analysis	p. 93
7.6.2 Maintainability Checklist	p. 94
7.6.3 Potential Accident/Damage Analyses	p. 94
7.6.4 Structured Interviews	p. 94
7.6.5 Critical Incident Technique	p. 95
7.6.6 Surveys	p. 95
7.7 Benefits of Human Factors Engineering Applications in Power Generation	p. 96
7.8 Problems	p. 96
References	p. 97
Chapter 8 Human Error in Aviation Maintenance	p. 99
8.1 Introduction	p. 99
8.2 Facts, Figures, and Examples	p. 99
8.3 Causes of Human Error in Aviation Maintenance and Major Categories of Human Errors in Aviation Maintenance and Inspection Tasks	p. 100
8.4 Types of Human Error in Aircraft Maintenance and Their Frequency	p. 100
8.5 Common Human Errors in Aircraft Maintenance Activities	p. 101
8.6 Aircraft Maintenance Error Analysis Methods	p. 101
8.6.1 Cause-and-Effect Diagram	p. 101
8.6.2 Error-Cause Removal Program (ECRP)	p. 102
8.6.3 Fault Tree Analysis	p. 104
8.7 Maintenance Error Decision Aid (MEDA)	p. 106
8.8 Useful Guidelines for Reducing Human Error in Aircraft Maintenance Activities	p. 107
8.9 Case Studies in Human Error in Aviation Maintenance	p. 109
8.9.1 Continental Express Embraer 120 Accident	p. 109
8.9.2 Air Midwest Raytheon (Beechcraft) 1900D Accident	p. 109
8.9.3 British Airways BAC1-11 Accident	p. 110
8.10 Problems	p. 110
References	p. 110
Chapter 9 Human Error in Power Plant Maintenance	p. 113
9.1 Introduction	p. 113
9.2 Facts and Figures	p. 113
9.3 Causes of Human Error in Power Plant Maintenance	p. 114
9.4 Maintenance Tasks Most Susceptible to Human Error in Power Generation	p. 116
9.5 Methods for Performing Maintenance Error Analysis in Power Generation	p. 116
9.5.1 Fault Tree Analysis	p. 116
9.5.2 Markov Method	p. 119
9.5.3 Maintenance Personnel Performance Simulation (MAPPS) Model	p. 122
9.6 Steps for Improving Maintenance Procedures in Power Generation and Useful Guidelines for Human Error Reduction and Prevention in Power Generation Maintenance	p. 122
9.7 Problems	p. 123
References	p. 124
Chapter 10 Safety in Engineering Maintenance	p. 127
10.1 Introduction	p. 127
10.2 Facts, Figures, and Examples	p. 127
10.3 Causes of Maintenance Safety Problems and Factors Responsible for Dubious Safety Reputation in Maintenance Activity	p. 128
10.4 Factors Influencing Safety Behavior and Safety Culture in Maintenance Personnel	p. 129
10.5 Good Safety-Related Practices during Maintenance Work and Maintenance-Related Safety Measures concerning Machinery	p. 129
10.6 Maintenance Safety-Related Questions for Engineering Equipment Manufacturers	p. 131
10.7 Guidelines for Engineering Equipment Designers to Improve Safety in Maintenance	p. 132
10.8 Mathematical Models	p. 132
10.9 Problems	p. 135
References	p. 136
Chapter 11 Mathematical Models for Performing Human Reliability and Error Analysis in Engineering Maintenance	p. 139
11.1 Introduction	p. 139
11.2 Models for Predicting Maintenance Personnel Reliability in Normal and Fluctuating Environments	p. 139
11.2.1 Model I	p. 140
11.2.2 Model II	p. 141
11.2.3 Model III	p. 145
11.3 Models for Performing Single Systems Maintenance Error Analysis	p. 147
11.3.1 Model I	p. 148
11.3.2 Model II	p. 150
11.4 Models for Performing Redundant Systems Maintenance Error Analysis	p. 153
11.4.1 Model I	p. 153
11.4.2 Model II	p. 156
11.5 Problems	p. 158
References	p. 159
Appendix	p. 161
Index	p. 175

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