An innovative approach to welding robot operator reliability analysis using extended TESEO and HEART methods

The paper presents a comprehensive identification and assessment of occupational hazards related to the operation of robotic welding systems. New technology fundamentally improves quality and accuracy of welds, especially precise narrow seams connecting thin sheets or profiles. The paper draws attention to typical occupational hazards occurring in the workplace, as well as those resulting from the use of robotic welding devices. Risk assessment was performed using the commonly used RISK SCORE method. Moreover, as part of our own research, the employee's reliability levels were determined by determining the probability of making a mistake. The human factor reliability study was carried out using HRA (Human Reliability Analysis) methods. The classic TESEO and HEART approaches have been expanded to include additional factors, such as human-machine interface (HMI), cognitive load, quality of documentation and procedures, and task ambiguity. This addition addresses a significant methodological gap in classic HRA analyses, which have so far overlooked these key aspects that influence the effectiveness and safety of human-robot interactions.