The Application of Lean Production in Reducing Human Error and Improving Response in Emergencies: A case Study in a Petrochemical Industry

Petrochemical industry is one of the most accident-prone industries, and most accidents in this industry are related to human factors. The principles of Lean production are one of the approaches used to improve the production situation. Various studies have shown that implementing Lean production improves the safety and ergonomics. In this study, the principles of Lean production were used to reduce human error and improve response in emergencies.

  The basic CREAM method was used to evaluate human errors. In order to select Lean production tools appropriate to the emergency response tasks, the opinions of the 20-member panel of specialists and experts, including industry managers, HSE officials, and university professors, were used. For examining the impact of Lean production principles on reducing human error in emergencies, 6 months after the implementation of Lean production interventions, human error was re-examined. Evaluation of human errors after Lean production interventions was also performed by basic CREAM method.

The results of the evaluation of human errors before and after the implementation of Lean production interventions showed that the level of control mode of the three sub-tasks improved from the tactical control mode to the strategic control mode. The most probable human error was in evacuate sub-task.

The results of this study showed that the implementation of those interventions that in addition to improving the level of safety, can improve organizational productivity, is more accepted by industry management.