Human Factor and Reliability Analysis to Prevent Losses in Industrial Processes

Human Factor and Reliability Analysis to Prevent Losses in Industrial Processes

An Operational Culture Perspective

1st Edition - March 23, 2022

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  • Authors: Salvador Filho, Ivone de Souza Cerqueira, Carine Nogueira Santino
  • Paperback ISBN: 9780128196502
  • eBook ISBN: 9780128196519

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Human reliability is an issue that is increasingly discussed in the process and manufacturing industries to check factors that influence operator performance and trigger errors. Human Factor and Reliability Analysis to Prevent Losses in Industrial Processes: An Operational Culture Perspective provides a multidisciplinary analysis of work concepts and environments to reduce human error and prevent material, energy, image, and time losses.    The book presents a methodology for the quantification and investigation of human reliability, and verification of the influence of human factors in the generation of process losses, consisting of the following steps: contextualization, data collection, and results; performing task and loss observation; socio-technical variable analyses; and data processing. Investigating human reliability, concepts, and models in situations of human error in practice, the book identifies where low reliability occurs and then visualizes where and how to perform an intervention. This guide is an excellent resource for professionals in chemical, petrochemical, oil, and nuclear industries for managing and analyzing safety and loss risks and for students in chemical and process engineering. 

Key Features

  • Relates human reliability to the environment, leadership, decision models, possible mistakes and successes, mental map constructions, and organizational cultures
  • Provides techniques for the diagnosis of human and operational reliability
  • Gives examples of the application of methodologies in the stage of diagnosis and program construction
  • Discusses competences for the analysis of process losses in industry
  • Investigates real-life situations where human errors cause losses
  • Includes practical examples and case studies


Professionals in chemical, petrochemical, oil, and nuclear industry managing and analyzing safety and loss risks; graduate students in chemical and process engineering; postgraduate students in management and process engineering

Table of Contents

  • Cover image
  • Title page
  • Table of Contents
  • Copyright
  • About the authors
  • Preface
  • 1 Paradigms
  • 2 Book structure
  • 3 Products related to the chapters
  • Acknowledgment
  • Chapter 1. Introduction
  • Abstract
  • 1.1 A brief discussion
  • 1.2 Discussion timeline and schools
  • 1.3 Worker role in job and society: human error
  • 1.4 Risk management on material losses and operations
  • References
  • Chapter 2. Human reliability and cognitive processing
  • Abstract
  • 2.1 Human reliability
  • 2.2 Human reliability and cognitive processing
  • References
  • Chapter 3. Factors affecting the performance of tasks
  • Abstract
  • 3.1 Human and social typology
  • 3.2 Task assessment
  • 3.3 Discussion about API 770
  • References
  • Chapter 4. Process loss assessment
  • Abstract
  • 4.1 Context
  • 4.2 Competencies to assess process losses
  • 4.3 Losses in the process industries
  • 4.4 Diagnosis of process losses
  • 4.5 Cases: diagnostics with quantitative and qualitative analysis
  • References
  • Chapter 5. Learned lessons: human factor assessment in task
  • Abstract
  • 5.1 Routine, environments, human types, and class of errors
  • 5.2 Routine learning: guidelines for human reliability
  • 5.3 Lessons learned and validation of the guidelines
  • 5.4 Human reliability, sociotechnical reliability, culture of safety demands
  • References
  • Chapter 6. Human reliability: SPAR-H cases
  • Abstract
  • 6.1 Introduction
  • 6.2 Concepts and SPAR-H calibration
  • 6.3 Case studies
  • 6.4 Comparative analysis
  • 6.5 Integrated reliability: the beginning
  • References
  • Chapter 7. Human reliability: chemicals and oil and gas cases
  • Abstract
  • 7.1 Methodology description
  • 7.2 Chemical industry case application
  • 7.3 Oil and gas case application
  • 7.4 Qualitative results: chemical industry cases
  • 7.5 Quantitative results: oil and gas case
  • 7.6 Future work: task cross-assessment based on particle swarm model
  • References
  • Chapter 8. Conclusion and products
  • Abstract
  • 8.1 Conclusion
  • 8.2 Future book: human factor routine and emergency analysis
  • 8.3 Products in general
  • 8.4 Product 1 (Chapter 4)—process loss mapping
  • 8.5 Product 2—task assessment—PADOP
  • 8.6 Product 3—cognitive quality
  • 8.7 Product 4—human reliability SPARH
  • 8.8 Product 5—social-technical reliability
  • 8.9 Product 6—operational-technical culture and prediction
  • References
  • Annex
  • A.1 Process loss map (Product 01)
  • A.2 Calibration of the SPAR-H method
  • A.3 Task assessment
  • A.4 Technical survey
  • A.5 Social typology
  • A.6 Human typology
  • A.7 Exercise
  • List of Abbreviations
  • Glossary
  • Index

Product details

  • No. of pages: 570
  • Language: English
  • Copyright: © Elsevier 2022
  • Published: March 23, 2022
  • Imprint: Elsevier
  • Paperback ISBN: 9780128196502
  • eBook ISBN: 9780128196519

About the Authors

Salvador Filho

Salvador Ávila Filho - Chemical Engineer (UFBA) and Petrochemical Processing (Petrobrás) applied his knowledge to the Chemical Industry. Specialized in: statistical techniques (CQE / ASQ) to investigate abnormalities in the industry and as Organizational Consultant (UCSal) for transformation of Culture. Developed auditing techniques, effluent control and fugitive emissions to reduce environmental impacts in the industry. He developed a technique that analyzes the perception of the operators regarding Clean Routines (UFBA). Acting as Manager of industrial facilities created model for Clean Management. As professor he taught disciplines in the Graduation of Administration, Chemical Engineering and of Production in Universities. Meanwhile, human aspects are investigated in the courses and practices of Psychoanalysis allowing to enter by the fault in the behavior in the society and the work. It has partnerships in the private initiative in Reliability Centered Maintenance (MCC) and Human Reliability. Doctoral research (UFRJ) in the human and organizational cultures area provides concepts, techniques and methods to keep processes under control. Articles were presented in the areas of Human Factors, Risk, Process Safety, Energy and Water Efficiency and currently in the area of Culture and Behavior Change. Work in the Energy area was developed with a solution for productive arrangements. Contributed to reduce the load of N effluent of the fertilizer industry with: statistics, process studies, equipment technology, investigation of procedures, educational campaign (Friends of the Lagoon). Professor and Researcher of UFBA in the Department of Mechanical Engineering conducts research and Services in the areas of Risk Management (RISKDYN); Organizational Culture and Human Reliability (EVOLUTION C; SARS; RECHA); loss of process, process, energy and water (P3NET; ELOS R) and operational. Currently has cooperation with: RLAM (Refinery) in the area of Energy Efficiency, UOBA Active North in the area of Reliability and Risk, Secretariat of Public Security in the area of Risk in Mega-event and Behavior of the police force of the State of Bahia

Affiliations and Expertise

University Federal da Bahia, Salvador, Brazil

Ivone de Souza Cerqueira

Ivone Conceição de Souza Cerqueira – Graduated in Nutrition from the Federal University of Bahia. Federal Public Servant, Ministry of Education - Federal University of Bahia, since 1982. Currently Coordinator of the Nucleus of Follow-up of Assessments of Undergraduate Courses - Pro Rectory of Undergraduate - UFBA. Specialist in Hospital Management by the Institute of Collective Health / UFBA, 1996. Specialist in Clinical Nutrition by the University of Navarro. Specialist in People Management by the School of Administration, UFBA. Master in Medicine and Health, Faculty of Medicine, UFBA. Member of the Communication and Health Research Group - UFBA Institute of Collective Health. Experience in International Hospital Accreditation in the areas of Education and Professional Qualification and Facilities Security. Post graduate in Security of Major Events - Centro Universitário Estácio da Bahia; Articles in the area of Security, Risk in Mega-event, Human Factor, Leadership and human reliability. Doctorate in Industrial Engineering - Polytechnic School - Federal University of Bahia-2017.1- 2020.1.

Affiliations and Expertise

Universidade Federal da Bahia, Salvador, Brazil

Carine Nogueira Santino

Carine Nogueira Santino – Graduated in Production Engineering from Salvador University. Master in Industrial Engineering from UFBA, working in the area of mapping losses in a metallurgical industry. Professional experience in the area of quality, where he performed activities in the area of quality in a Steel Industry, involving audits and Six Sigma project; has experience in the area of people management, working for 4 years in Human Resources. Member of the Research Group GRODin-Polytechnic School-UFBA- research group at risk dynamic, and topics that address reliability safety and reduction of environmental impacts. Articles in the areas of process safety, human reliability and loss mapping

Affiliations and Expertise

Universidade Federal da Bahia, Salvador, Brazil

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