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A Markov-based model to mitigate human errors occurrence during maintenance activities in petrochemical systems

Author

Listed:
  • Laith A. Hadidi

    (King Fahd University of Petroleum and Minerals
    King Fahd University of Petroleum and Minerals)

  • Ahmed Ghaithan

    (King Fahd University of Petroleum and Minerals
    King Fahd University of Petroleum and Minerals)

  • Awsan Mohammed

    (King Fahd University of Petroleum and Minerals
    King Fahd University of Petroleum and Minerals)

  • Naif Alhwoaikan

    (King Fahd University of Petroleum and Minerals)

Abstract

Human errors aren’t uncommon in maintenance operations to disrupt the scheduled maintenance tasks with adverse consequences on equipment, personnel, or environment. Yet, human error can’t be simply detected during maintenance operation (only after the commissioning). The consequences for such unintended errors may be drastic in petrochemical industries especially under severe operation conditions. The purpose of this study is to explore root cause analysis for human errors in Preventive Maintenance (PM) activities in petrochemical industry. The paper collects the data of poor maintenance incidents from ERP system in one of the largest oil and gas facilities in Saudi Arabia. The incidents analysis indicates 103 failure caused by human errors during the analysis periods from year 2010 till 2019. The findings show that lacking in quality assurance and quality control program is the main cause to have repetitive human failures in PM tasks. Accordingly, a Markov-based model is developed to simulate the improvement effect of having quality assurance and quality control programs as part of the PM tasks. Interestingly, the availability of the equipment is improved by 20% with the quality assurance program and the probability to have human errors dropped to less than 5%.

Suggested Citation

  • Laith A. Hadidi & Ahmed Ghaithan & Awsan Mohammed & Naif Alhwoaikan, 2023. "A Markov-based model to mitigate human errors occurrence during maintenance activities in petrochemical systems," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 14(6), pages 2146-2159, December.
    • Handle: RePEc:spr:ijsaem:v:14:y:2023:i:6:d:10.1007_s13198-023-02045-5
    DOI: 10.1007/s13198-023-02045-5
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    References listed on IDEAS

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    1. Marais, Karen B. & Robichaud, Matthew R., 2012. "Analysis of trends in aviation maintenance risk: An empirical approach," Reliability Engineering and System Safety, Elsevier, vol. 106(C), pages 104-118.
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    3. Eti, Mark C. & Ogaji, S.O.T. & Probert, S.D., 2006. "Strategic maintenance-management in Nigerian industries," Applied Energy, Elsevier, vol. 83(3), pages 211-227, March.
    4. Marco Macchi & Klodian Farruku & Maria Holgado & Elisa Negri & Daniele Panarese, 2016. "Economic and environmental impact assessment through system dynamics of technology-enhanced maintenance services," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 23(1), pages 36-56.
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