This study compared the results of the application of two different methodological frameworks to identify the critical functions in a chemical industry that affect process safety. The Functional Resonance Analysis Method (FRAM) and Performance Shaping Factors (PSF), the latter involving operators' active participation, were applied on the same socio-technical process. Three phenotype responses were integrated, based on FRAM, namely timing, precision, and duration. The ergonomics approach was used to identify process functions by observing the operator workday to FRAM. A methodological framework based on human factors had selected the critical key PSF, used as an indicator, to identify the critical activities in the process, by operator's perceptions. This study demonstrated that some result variability couplings can be different in some aspects in the automated and batch process. The integration of duration phenotypes with integration time and precision can modify the results of variability in the batch process. Human being management adapts and mitigates the risk. Operator competence and knowledge can eliminate function and task time by modifying the work sequence of the process. Comparison of analytical results demonstrated the compatibility of the two analyses.
This work presents a multidisciplinary methodology for the identification of critical activities in an industrial process utilizing task time quantification techniques present in ergonomic analysis and involving the participation of socio-technical users. It involved an activity analysis that focused on the individual workers' functions and behavior when carrying out their tasks in a metallurgy electrolysis unit. The choice of critical activities was based on levels of exposure to occupational, environmental and operational health risks present during the working period. The methodology identified critical activities that put both the health and safety of the workers at risk. The operators' participatory and constructive approach reduced analytical subjectivity, providing consensual conclusions. Questionnaires were used to produce a pain map that sought to analyze the stress placed on the workers' musculoskeletal system as a consequence of performing their activities. The quantification of time in the operator's workday identified the criticality of exposure to occupational health risks associated with the operational procedure. A process validation was reached, which integrated a postural and kinesiological analysis with the operators' perceptions according to their responses to questionnaires. As a result of the analysis undertaken in this work it was also possible to identify an increase in deformities present in copper cathodes and a corresponding increase in on-time activities to remove them that had led to production losses as well as worker discomfort. The methodology, which included the operators' opinions and perceptions, concluded with a process validation. This work describes a set of proposed metrics based on ergonomic principles.
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