Approach to analyse hazardous situations tied to recurrent production dysfunctions, by observing the work situation

When using a machine or automated system, dysfunctions such as jamming of a part can occur and disturb the normal production process. To solve this dysfunction, the operator may place himself in a hazardous situation. We propose an approach to identify these potentially hazardous situations by observing the work situation. The feasibility of this approach was tested on an oil pump assembly line. The approach comprises two phases: a detection phase of both the dysfunction and the response of the operator to solve it, followed by an analysis phase aimed at envisaging hazard scenarios and evaluating their associated risks. A cause and effect relationship between the dysfunction, the operator's response and the risks incurred has been established. The results of the risk analysis of the proposed approach complete the initial analysis of the risks of the workstation performed by the company to take into account the impacts of production dysfunctions.