Dynamic modeling of human error in industrial maintenance through structural analysis and system dynamics

Abstract Human error constitutes a significant cause of accidents across diverse industries, leading to adverse consequences and heightened disruptions in maintenance operations. Organizations can enhance their decision‐making process by quantifying human errors and identifying the underlying influencing factors, thereby mitigating their repercussions. Consequently, it becomes crucial to examine the value of human error probability (HEP) during these activities. The objective of this paper is to determine and simulate HEP in maintenance tasks at a cement factory, utilizing performance shaping factors (PSFs). The research employs the cross‐impact matrix multiplication applied to classification (MICMAC) analysis method to evaluate the dependencies, impacts, and relationships among the factors influencing human error. This approach classifies and assesses the dependencies and impacts of different factors on HEP, occupational accidents, and related costs. The study also underscores that PSFs can dynamically change under the influence of other variables, emphasizing the necessity to forecast the behavior of human error over time. Therefore, this paper utilizes the MICMAC method to analyze the interdependencies, relationships, and impact levels among different variables. These relationships are then utilized to optimize the implementation of the system dynamics (SD) method. An SD model is employed to forecast the system's behavior, and multiple scenarios are presented. By considering the HEP value, managers can adjust organizational conditions and personnel to ensure acceptability. The paper also presents various scenarios related to HEP to assist managers in making informed decisions.