Objective: The purpose of this study is to systematically investigate cases of stuck accidents in the manufacturing industry and ergonomically analyze human errors.
Background: In the manufacturing industry, stuck accidents account for a significantly high proportion of work-related incidents. To ensure fundamental safety in high-risk human-machine collaboration environments, systematic research on human errors from an ergonomic perspective is necessary.
Method: This study collected a database of stuck-related fatal accidents that occurred in the manufacturing industry from 2017 to 2019. The occurrence patterns of stuck accidents were classified into six types: stuck between stuck between equipment or machinery in linear motion, entangled with rotating parts and protrusions, stuck at the nip points of two rotating parts, stuck between rotating parts and stationary objects, Stuck by objects during manual handling, and Others. In this study, ergonomic human errors were classified into three categories: error mechanisms (primary, command, secondary), information processing errors (unintended actions—slip, lapse; intended actions—mistake, violation), and incorrect human outputs (omission; commission —selection, sequence, time, qualitative). A chi-square test was conducted to statistically analyze the significance of differences within and between groups based on the frequency of human error types and accident occurrences.
Results: This study analyzed human errors in a total of 187 cases of stuck-related fatal accidents. The frequency analysis of error mechanisms revealed that primary and command errors were the most prevalent (342 cases, 99.4%), and statistical analysis using the chi-square test showed a significant difference (p<0.0001). The endogenous (e.g., inattention, risk-taking) and exogenous (e.g., distractions, interruptions, system interface issues) factors of workers were identified as the primary causes of human errors. The frequency analysis of information processing errors revealed that violation errors were the most prevalent (170 cases, 45.9%), and statistical analysis using the chi-square test showed a significant difference (p<0.0001). Workers' motivation to violate regulations may increase when appropriate rewards for compliance are not provided, or when violations are tolerated or inadequately punished. Therefore, to reduce intended violations, the introduction of a safety reward system and the development of a committed safety culture within the organization are necessary. The frequency analysis of incorrect human outputs errors revealed that omission errors were the most prevalent (173 cases, 82.4%), and statistical analysis using the chi-square test showed a significant difference (p=0.0009). The frequency analysis of accident occurrences revealed that stuck between stuck between equipment or machinery in linear motion had the highest frequency, and statistical analysis using the chi-square test showed a significant difference (p<0.0001).
Conclusion: To reduce intended violations, it is necessary to develop reasonable, site-specific safety guidelines that reflect the characteristics of the workplace, based on universal work safety manuals. To encourage safe behavior, a safety management system should be implemented, grounded in a strong safety culture.
Application: The results of this study may contribute to the prevention of frequently occurring stuck accidents in the manufacturing industry. Furthermore, it is expected that this research will help reduce the stagnant fatal accident rate and transform the paradigm of industrial safety.