Simulation-Based Countermeasures Towards Accident Prevention : Virtual Reality Utilization in Industrial Processes and Activities

Despite growing industrial interests in fully immersive virtual reality (VR) applications for safety countermeasures, there is scanty research on the subject in the context of accident prevention during manufacturing processes and plant maintenance activities. This dissertation aims to explore and experiment with VR for accident prevention by targeting three workplace safety countermeasures: fire evacuation drills, hazard identification and risk assessments (HIRA), and emergency preparedness and response (EPR) procedures. Drawing on the virtual reality accident causation model (VR-ACM) (i.e., 3D modelling and simulation, accident causation, and safety drills) and the fire evacuation training model, two industrial 3D simulation models were utilized for the immersive assessment and training. These were a lithium-ion battery (LIB) manufacturing factory and a gas power plant (GPP). In total, five studies (publications) were designed to demonstrate the potential of VR in accident prevention during the manufacturing processes and maintenance activities at the facility conceptual stages. Two studies were with the LIB factory simulation to identify inherent hazards and assess risks for redesigning the factory to ensure workplace safety compliance. The other three studies constituted fire hazard identifications, emergency evacuations and hazard control/mitigations during the maintenance activity in the GPP simulation. Both study models incorporated several participants individually immersed in the virtual realm to experience the accident phenomena intuitively. These participants provided feedback for assessing the research objectives. Results of the studies indicated that several inherent hazards in the LIB factory were identified and controlled/mitigated. Secondly, the GPP experiment results suggested that although the maintenance activity in the virtual realm increased the perception of presence, a statistically significant delay was recorded at the pre-movement stage due to the lack of situational safety awareness. Overall, the study demonstrates that participants immersed in a VR plant maintenance activity and manufacturing factory process simulation environments can experience real-time emergency scenarios and conditions necessary for implementing the essential safety countermeasures to prevent accidents.Vaikka kiinnostus virtuaalitodellisuuden (VR) käyttöön turvallisuuden varotoimissa teollisuudessa on kasvanut, tutkimuksia ei ole juurikaan tehty onnettomuuksien ehkäisystä valmistus- ja kunnossapitotoiminnassa. Tämän väitöskirjan tavoitteena on tutkia ja kokeilla VR:ää tapaturmien ehkäisyssä kohdistuen kolmeen työpaikan turvallisuuden varotoimeen: paloharjoitukset, riskien arvioinnit sekä hätätilanteiden valmiusmenettelyt ja toimintasuunnitelmat (EPR). Kokemuksellisessa ja uppouttavassa koulutuksessa hyödynnettiin kahta teollisuuden 3D-simulointimallia, jotka nojautuvat virtuaalitodellisuuden onnettomuuksien aiheutumismalliin (VR-ACM) (eli 3D-mallinnus- ja simulointi, onnettomuussyy- ja turvallisuuskoulutus) sekä paloharjoitusmalliin. Nämä 3D-simulointimallit ovat litiuminoniakkuja (LIB) valmistava tehdas, joka rakennettiin Visual Components 3D-simulointiohjelmistolla (versio 4.0) ja kaasuvoimala (GPP) Unrealin reaaliaikaisella pelimoottorilla (versio 4.2). Yhteensä viisi tutkimusta (julkaisua) suunniteltiin havainnollistamaan VR:n potentiaalia tapaturmien ehkäisyssä valmistusprosessin layout-suunnittelun ja tehtaan konseptivaiheissa tehtävän kunnossapidon aikana. Kaksi tutkimusta tehtiin LIB-tehdassimulaatiolla vaarojen tunnistamiseksi sekä riskien arvioimiseksi. Tutkimukset tehtiin tehtaan uudelleensuunnittelua varten, työturvallisuuden noudattamisen varmistamiseksi. Muut kolme tutkimusta käsittelevät palovaaran tunnistamista, hätäevakuointia ja riskien vähentämistä huoltotoiminnan aikana GPP-simulaatiossa. Molemmissa tutkimusmalleissa oli useita virtuaalimaailmaan uppoutuneita osallistujia, jotka saivat kokea onnettomuudet yksilöllisesti ja intuitiivisesti. Osallistujat antoivat palautetta kokeen jälkeisessä kyselyssä. Kyselyn tuloksien avulla LIB-tehtaassa tunnistettiin ja lievennettiin useita vaaroja. GPP-kokeilun tulokset viittasivat siihen, että vaikka ylläpitotoiminta virtuaalimaailmassa lisäsi teleläsnäoloa, tilastollisesti merkittävä viive kirjattiin liikettä edeltävässä vaiheessa turvallisuustietoisuuden puuteen vuoksi. Kaiken kaikkiaan tutkimus osoittaa, että VR-laitoksen kunnossapitotoimintaan ja tuotantotehtaan prosessisimulaatioympäristöihin uppoutuvat osallistujat voivat kokea reaaliaikaisia hätäskenaarioita ja olosuhteita, jotka ovat välttämättömiä olennaisten turvallisuustoimien toteuttamiseksi.fi=vertaisarvioitu|en=peerReviewed

A Study of Safety Culture Assessment Framework for Process Industries and Its Application to a Bayesian Belief Network Analysis

Investigations of major catastrophes in process industries have revealed that deficiency of good safety culture is one of the underlying causes of such disasters. Not only has safety culture been recognized as a root cause, but also it is increasingly accepted as an influential factor in a risk analysis and considered as a legal requirement. Most of current quantitative risk analyses (QRA) rely on technical factors but more and more effort is being made for the incorporation of human and organizational factors (HOFs). Especially, safety culture largely represents an organizational attitude towards safety. Thus, how to measure safety culture in more effective manners and how to utilize such assessment data in a QRA are chosen as major objectives of this research. For the measurement of safety culture, this study suggests an approach that assesses values and assumptions by looking through artifacts, e.g., management level and employee’s behavior. Such approach employs following two methods: a matrix structure composed of safety culture dimensions, and grading schemes that provide different levels of safety practices. Using such an approach and suggested methods, a safety culture assessment questionnaire is developed as a results. For the incorporation of such safety culture data into a risk analysis, this study employs a risk model based on Hybrid Causal Logic (HCL) and a Bayesian Belief Network (BBN) to represent cause and effect relationships among variables. Mock-up safety culture data is generated for this analysis. Findings from investigation of Universal Form Clamp incident (2006) are used to establish a case scenario upon which a fault tree and an event tree are constructed. To make a transition from qualitative knowledge about safety culture to quantitative probability data, some of the safety culture dimensions are selected as Risk Influencing Factors (RIFs), while Safety Culture Influencing Factors (SCIFs) are developed and introduced in this work. Using the established BBN, prior generic probability data are updated with newly obtained evidences such as mock-up safety culture assessment data. In addition, several analyses, e.g., predictive and diagnostic reasoning are conducted to determine how a change in safety culture affects the probabilities of safety-related events and also to identify which safety culture aspects need improvement

Risk Management for the Future

A large part of academic literature, business literature as well as practices in real life are resting on the assumption that uncertainty and risk does not exist. We all know that this is not true, yet, a whole variety of methods, tools and practices are not attuned to the fact that the future is uncertain and that risks are all around us. However, despite risk management entering the agenda some decades ago, it has introduced risks on its own as illustrated by the financial crisis. Here is a book that goes beyond risk management as it is today and tries to discuss what needs to be improved further. The book also offers some cases

Robust product architecture development combining matrix-based approaches and function-based failure propagation method: M-FBFP framework

Ovaj rad predlaže okruženje M-FBFP sa ciljem da se pomogne konstruktorima prilikom rešavanja problema sa rizikom, koji se pojavljuje u arhitekturi proizvoda, te sa efektima pri radu u neizvesnim radnim uslovima. Predloženo okruženje predstavlja kombinaciju matrično baziranih pristupa (QFD i MDM) i FBFP metode. QFD pristup je integrisani skup alata za prikupljanje zahteva korisnika, inženjerskih karakteristika, koje zadovoljavaju te zahteve, te ostalih veza između inženjerskih karakteristika, dok se MDM pristup primenjuje za modeliranje struktura i zavisnosti između domena, te unutar samih njih. FBFP metoda se primenjuje na funkcionalnom nivou, te nam daje potencijalnu informaciju o nedostatku ili grešci u samim funkcijama proizvoda i njegovim podsistemima tokom faze projektovanja. Kao rezultat ovog okruženja, moguće je sprovesti analizu rizika u podsistemima proizvoda i samim tim dobiti povratnu informaciju, da li je nešto u predloženoj arhitekturi potrebno dodati ili promeniti. U okviru ovog rada prikazan je primer klima-komore sa regeneracijom toplote, čime je prikazan princip rada predloženog okruženja.This paper proposes an M-FBFP framework with the objective to help designers tackle the problem of risk emerging from product architecture and the effects of uncertain operating conditions. The proposed framework combines matrix approaches (QFD and MDM) and the FBFP method. The QFD is an integrated set of tools for recording user requirements, engineering characteristics that satisfy these requirements, and any tradeoffs that might be necessary between the engineering characteristics, while the MDM is applied to model structural arrangements and dependencies between the domains and within themselves. The FBFP method, on the other hand, is applied at the functional level, provides potential failure information based on product functions during conceptual design in product subsystems. As a result of the proposed framework, risk analysis of subsystems becomes possible and feedback on product architecture could be provided. To test validity of the proposed approach, here is presented a case study with climate chamber with heat regeneration

Risk Assessment as a Tool for Mobile Plant Operators for Sustainable Development: Lessons from the Western Australian Mining Industry

Mobile plant is used extensively not only in the Western Australian (WA) Mining Industry but internationally as well. The use of mobile plant has inherently high risk and every year is associated with a significant number of workplace fatalities and injuries. Prior to this research being conducted there was no specific data published related to mobile plants incidents and fatalities for the Western Australian mining industries. The aim of this research was to improve the safety performance of mobile plant operators in the Western Australia (WA) mining industry by identifying the causes of mobile plant incidents reported to Resources Safety between 1/1/2007 and 31/3/2020

Human error reduction program in SilTerra Malaysia Sdn Bhd: applying Canonical action research (CAR)

SilTerra Malaysia Sdn Bhd (SMSB) is a Malaysian’s premier wafer fabrication, a high technology company owns by Khazanah Nasional Berhad. Although there are engineering platforms and automation systems in place, human errors still occur among the wafer fabrication personnel, causing a huge loss every year. This research aimed to determine the factors that contribute to human errors. The factors then serve as the input for establishing SilTerra Small Group Activity (SSGA) to reduce human error excursion events in the Manufacturing Department. Canonical action research (CAR) was used as the basis in the research methodology. This research employed both the quantitative and the qualitative approaches, whereby 119 technicians participated in a survey that represented 25% of the total manufacturing population in SMSB. The survey was conducted to identify the factors that contribute to human errors in the Manufacturing Department. In addition, secondary data and feedback from the focus group that consisted of top management personnel were gathered to support the understanding of human error contributors. The research findings indicated that there are two main Human Error Classifications in SMSB, and they are Decision Error as well as Perceptual Error. The SSGA program, which has been continuously conducted, has shown a significant reduction in human error excursion events. The theoretical contribution in the Human Factors Analysis and Classification System (HFACS) applied in this research has significantly contributed to a meaningful result. This research focused mainly on human errors contributed by errors and violations. Other factors such as environmental factors, condition of operators and personal factors can be investigated in future studies. Besides, it will be interesting to extend the research to other types of manufacturing industries

Pour une meilleure prise en charge de la SST : une nouvelle démarche pratique de gestion des risques de projets miniers

Bien que l’industrie minière utilise convenablement les outils de gestion des risques, certains projets miniers d’envergure ont rencontré de nombreux problèmes dus à un manquement de prise en considération de la santé et de la sécurité du travail (SST). Malgré le degré élevé des risques et des incertitudes relié à l’exploitation d’un projet minier, il n’existe qu’un nombre limité de recherches proposant de gérer tous les risques identifiés de façon systématique. Cette insuffisance est parfois expliquée par le manque de fiabilité des données et les carences relatives à l’expertise permettant d’identifier et d’évaluer convenablement tous les risques miniers. Dans un contexte économique en pleine effervescence, l’industrie minière doit relever plusieurs défis en lien avec le démarrage de nombreux projets. Dans un environnement très complexe et incertain, une gestion rigoureuse des risques demeure une composante indispensable pour contourner plusieurs menaces. Étant donné la complexité de ces projets, plusieurs entreprises minières cherchent continuellement à améliorer et créer des démarches intégrées de gestion des risques. Dans cette thèse, nous proposons une nouvelle démarche par facteurs de risques pour intégrer la SST, de façon systématique et systémique, dans la gestion des risques de projets miniers. Cette démarche est appuyée sur un nouveau concept, la « concentration des sources de dangers », et sur la méthode d’analyse multicritère AHP (Analytical Hierarchy Process). Les travaux de recherche ont pour finalité la généralisation progressive de l’utilisation de cette démarche dans le secteur des mines d’or au Québec. En plus de la démarche proposée, de ses outils et de ses nouveaux concepts, nous fournissons à la communauté scientifique et aux praticiens un portrait préliminaire des risques associés aux projets miniers. Ce portrait de risques est indispensable pour compléter une évaluation fiable et rapide des risques de projets miniers. Nous partageons également deux bases de données évolutives comportant chacune plus de 200 sources de dangers élaborées relativement à deux mines d’or (à ciel ouvert et souterraine). Ces bases de données servent comme bases de connaissances évolutives et potentiellement adaptables et transférables à d’autres entreprises, de même qu’à d’autres nouveaux projets miniers. Les travaux de recherche ont permis à nos partenaires industriels d’identifier et de prioriser les risques potentiels afin qu’ils puissent choisir la meilleure stratégie de contrôle. Plusieurs équipes interdisciplinaires ont été impliquées dans cette recherche, favorisant ainsi un partage du savoir-faire industriel. Enfin, cette recherche a permis une prise en considération de la SST dans toutes les activités opérationnelles des mines impliquées. Malgré ces efforts, cette thèse présente plusieurs limites parmi lesquelles on retrouve certaines que nous envisageons de résoudre dans un avenir rapproché. En premier lieu, nous nous proposons d’utiliser la méthode Delphi en vue d’atteindre un consensus entre les experts, dans le but de valider une échelle de conversion des « concentrations des sources de dangers » en probabilités. Nous envisageons également d’explorer les possibilités d’ajout d’autres techniques de collecte de données mieux adaptées aux problématiques et risques étudiés. Seulement deux entreprises minières au Québec ont mis en oeuvre la démarche de gestion des risques proposée. L’influence de la culture des organisations sur la démarche proposée reste un obstacle important quant à la généralisation des résultats de la thèse. Nous essayons de remédier à cette contrainte par une présence plus étendue dans le secteur, ainsi que par le suivi de nos partenaires industriels

Risk Assessment and Management of Petroleum Transportation Systems Operations

Petroleum Transportation Systems (PTSs) have a significant impact on the flow of crude oil within a Petroleum Supply Chain (PSC), due to the great demand on this natural product. Such systems are used for safe movement of crude and/or refined products from starting points (i.e. production sites or storage tanks), to their final destinations, via land or sea transportation. PTSs are vulnerable to several risks because they often operate in a dynamic environment. Due to this environment, many potential risks and uncertainties are involved. Not only having a direct effect on the product flow within PSC, PTSs accidents could also have severe consequences for the humans, businesses, and the environment. Therefore, safe operations of the key systems such as port, ship and pipeline, are vital for the success of PTSs. This research introduces an advanced approach to ensure safety of PTSs. This research proposes multiple network analysis, risk assessment, uncertainties treatment and decision making techniques for dealing with potential hazards and operational issues that are happening within the marine ports, ships, or pipeline transportation segments within one complete system. The main phases of the developed framework are formulated in six steps. In the first phase of the research, the hazards in PTSs operations that can lead to a crude oil spill are identified through conducting an extensive review of literature and experts’ knowledge. In the second phase, a Fuzzy Rule-Based Bayesian Reasoning (FRBBR) and Hugin software are applied in the new context of PTSs to assess and prioritise the local PTSs failures as one complete system. The third phase uses Analytic Hierarchy Process (AHP) in order to determine the weight of PTSs local factors. In the fourth phase, network analysis approach is used to measure the importance of petroleum ports, ships and pipelines systems globally within Petroleum Transportation Networks (PTNs). This approach can help decision makers to measure and detect the critical nodes (ports and transportation routes) within PTNs. The fifth phase uses an Evidential Reasoning (ER) approach and Intelligence Decision System (IDS) software, to assess hazards influencing on PTSs as one complete system. This research developed an advance risk-based framework applied ER approach due to its ability to combine the local/internal and global/external risk analysis results of the PTSs. To complete the cycle of this study, the best mitigating strategies are introduced and evaluated by incorporating VIseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR) and AHP to rank the risk control options. The novelty of this framework provides decision makers with realistic and flexible results to ensure efficient and safe operations for PTSs