Study Of Human Error Classification And Control In Automotive Gearbox Assembly Line

Along with the development of science and technology, the production systems become more automated, and the reliability of equipments are improved greatly. However, the output of the operator fluctuate from time to time because of the factors such as physical, psychological, social, spiritual and so on, it cause the operation reliability decreased comparatively. Besides, the production systems become more automated doesn't mean the operators'influence on the whole system been reduced, the operator relatively more important to the system. Nowadays, more and more quality accidents are caused by human errors. At the same time, Total Quality Management, the third stage of quality management, has come, which emphasizes "people-oriented" and "full participation"; and highlights the core status of human. Therefore, the research on the human errors of the production systems becomes significant.This paper focus on the automotive gearbox assembly line. Through the survey of the line we found that the losses caused by quality accident exceed more than 80 million yuan, and 80% of accidents are related to the relevant operator directly. So, improving the operation reliability of production systems is extremely important. In the paper, quality accident of assembly line is the starting point. We select a representative assembly process as the main object, then we analysis the operation errors of the operators, find out the main influence factor, raise control methods so that we can reduce the quality accident.The chapter one depicts the research's background, importance and purpose .The assembly line is a special Man-machine system, the operation reliability of which has a direct influence on the system reliability, the influence is reflected in the human related quality accident. The economic interests of enterprise is the survival base, only produced the high-quality products with low cost, the enterprise can gain the preponderance The research on the human related quality accident. Is focus on reducing the cost and accident rate.The second chapter defines the human error and introduces the development of the domain. The human error research belongs to the human reliability engineering. Then, this chapter presents the relationship between human error and human reliability, analysis the characteristics of human error and introduces the previous research on the human error theory to explain the mechanism. The human is essentially different from the machine, so the analysis way is different. The study of human behavior must be integrated with psychology, also must be analyzed from the whole action process, so this chapter discusses the cognitive psychology and the operators'cognitive actions.The chapter three begins with the classification of the three representative human errors in the assembly of axis two using the classic classification methods. Then, this chapter analyzes the controllability of the three errors and we find out that the three human errors are all controllable. In order to construct the evaluation guidelines of the human errors, this chapter makes use of the Process Failure Mode Effects Analysis PFMEA) to analysis the human errors, though this method we find the value of RPN exceeds the acceptable range, so it is imperative for us to analysis the three error so that to avoid the huge lose in the future.The chapter four analysis the mechanism of the three errors and proposes the control methods for the error factors. With the cognition trace of the operation process, we descript the human error clearly and we get the error parts are Information Perception Error, Information Recovering Error, Information Matching Error, Action Intention Error and Rule Selecting error. We can classify these error parts into three categories: Perception Error, Decision Error and Action Error. Though the analysis we get the error factors are time pressure, perception shortage, the feature of the ring, the characteristics of the operator and so on. In order to reduce the human error rate, this chapter proposes a few error proofs to control the error factors, and we use the PFMEA to evaluate the control effect, it proves effective.The last chapter of this paper focus on the factors of time pressure and perception shortage gained from chapter four. This chapter designs two tests to prove the influence effect of the two factors to the operation. Though the test, we find out that these two factors have obvious influence effect on the operation. In order to control the two factors, this chapter proposes bulk distribution of tasks and reinforce the perception trainings to the operators, though the control group, we find the effect is obvious.In summary, this thesis analyzes the classic human errors of the second axis assembly process in the automotive gearbox assembly line. At the first step, the paper classifies the three human errors using the classic method, analyzes the controllability of these errors. Then, the paper uses the PFMEA to analyze the human errors and the PFMEA can be the guideline of the human error control. In order to propose the control method, the paper analysis the error process thoroughly. With the cognition trace of the operation process, we descript the human error clearly, then this paper proposes a few error proof methods to control the error factors. The error proof methods can be classified into two kinds: Physics Error Proof Method and psychological Error Proof Method. The paper proposes a few physics error proof methods, though the PFMEA, the value of RPN can be reduced to the acceptable range. Besides, the paper proposes physics error proof methods, it proves effective though two test designed by the researcher, this can be a reference for the factory.