Understanding human error
Human error is one of the primary causes of problems in manufacturing. Discover the root causes and learn how technology and motivation strategies can help reduce mistakes.
Root causes of human error
Understanding why errors happen is the first step to preventing them.
Fatigue and long shifts
Fatigue is a major contributor to errors, especially during night shifts or extended working hours. Tired workers are more prone to lapses in judgment, slower reaction times, and reduced attention to detail.
Low motivation
Employees who are disengaged or under stress are more likely to overlook details or rush through tasks, increasing the risk of error. A lack of motivation can stem from poor work conditions, lack of incentives, or feeling undervalued.
Training and inexperience
Inexperience leads to mistakes in handling equipment, following procedures, or understanding safety guidelines. Workers often skip steps in maintenance procedures because they don't fully understand the process.
Real-life examples
An untrained operator caused a critical failure by incorrectly programming a machine, resulting in hours of downtime and significant financial loss.
Errors due to rushed work at a chemical plant led to a spill, posing safety risks and halting production.
Technology solutions to reduce errors
Modern technology provides powerful tools to prevent human error and improve safety.
Workforce management
Optimize schedules based on workers' fatigue levels and performance data, helping to reduce errors caused by exhaustion.
Digital work instructions
Provide real-time accessible instructions through tablets, mobile devices, or voice commands on the factory floor. Workers can follow visual and text-based instructions, reducing errors due to miscommunication or forgotten steps.
Error detection & monitoring
Continuously analyze machine performance to prevent breakdowns or faulty production by identifying warning signs that humans might miss.
Augmented reality (AR)
Deliver real-time, visual work instructions and help workers identify issues during production, significantly reducing the chance of errors caused by inexperience or distractions.
Performance analytics
Identify trends such as frequent errors made by certain individuals or during specific shifts. This allows management to provide targeted training or adjust processes to improve performance.
Integrated training platforms
Virtual simulations and training environments where workers can learn complex machinery processes before stepping onto the factory floor, reducing errors caused by lack of experience.
Keeping workers engaged and motivated
Motivated employees make fewer mistakes and contribute more to safety and quality.
Gamification of work performance
Reward employees for using new tools or software effectively, with badges, points, or leaderboard rankings based on their adherence to digital work instructions, use of real-time monitoring systems, or performance improvements.
Software adoption to career development
Offer certifications for mastering specific tools, like predictive maintenance software or AR work instruction platforms, that can be tied to opportunities for career advancement.
Incentive-based bonuses
Implement a system where workers or teams earn bonuses for meeting error-free production goals, reducing downtime, or using automated tools to prevent safety incidents. These bonuses can be tied to data generated by digital systems.
Rewards for innovation
Encourage employees to suggest improvements or innovative solutions during maintenance and production. Reward workers who propose effective innovations or share valuable knowledge that reduces downtime, improves efficiency, or increases safety.
Ready to reduce human error in your factory?
Let us help you implement the right technology and motivation strategies to minimize mistakes and improve safety.