Human errors in manual assembly - A survey on current and future relevance

Causing rework, scrappage, and product recalls, human errors are a primary cost driver within production. Product defects are one of the seven types of waste within the lean philosophy. Hence, errors causing those imperfect products must be avoided. However, demographic change leading to an older workforce, combined with an expected shortage of skilled workers, on the one hand, and increasing demands on workers due to growing product variety and individualization, on the other, may lead to an increased likelihood of errors in the future. Existing literature focuses on error probabilities, e.g., in Human Reliability Analysis, or root-cause analyses of existing errors, e.g., Failure Modes and Effects Analysis. To further expand existing concepts, it is necessary to assess industrial needs first. Hence, this article introduces a survey on the relevance of human errors within manual flow assemblies and preventive measures for error avoidance. Overall, the respondents' opinions show a rising relevance of human errors in the area considered, with preventive measures becoming more relevant. Furthermore, there is a high degree of subjectivity in the decision-making on suitable preventive measures. This indicates a need for a more systematic and holistic approach to decide on preventive measures to be taken, not only focusing on technical avoidance strategies.