Investigation of Human Factors Contributing to Accidents and Unsafe Acts of Employees and Their Prioritization Using HFACS, DEMATEL, and ANP Methods: A Case Study in the Rebar Production Unit of a Steel Manufacturing Company

Farnaz  Asghari; Rasoul  Hemmatjou; Abolfazl  Ghahramani

doi:10.18502/jhsw.v15i3.21418

Farnaz Asghari Department of Occupational Health, Faculty of Health, Urmia University of Medical Sciences, Urmia, Iran
Rasoul Hemmatjou Department of Occupational Health, Faculty of Health, Urmia University of Medical Sciences, Urmia, Iran
Abolfazl Ghahramani Department of Occupational Health, Faculty of Health, Urmia University of Medical Sciences, Urmia, Iran

DOI: https://doi.org/10.18502/jhsw.v15i3.21418

Keywords: HFACS, human error, unsafe acts, DEMATEL, ANP, Steel

Abstract

Introduction: Unsafe acts are one of the main causes of workplace accidents. Given the critical role ofthe steel industry in our country, and the limited research on human factors, and the importance ofidentifying the contributors to accidents, this study was conducted with the aim of identifying humanfactors influencing accidents and unsafe behaviors using the Human Factors Analysis and ClassificationSystem (HFACS). The identified factors were then prioritized using the Decision-Making Trial and EvaluationLaboratory (DEMATEL) and Analytic Network Process (ANP) methods. Based on the results, appropriaterecommendations were proposed for the prevention of accidents and the reduction of unsafe acts.

Material and Methods: This descriptive-analytical study was carried out in the rebar production unit of asteel manufacturing plant. Among 35 recorded accidents over the past two years, 28 were related to therebar production unit. Data were collected through review of accident reports, seven on-site observationsduring high-risk shifts, and interviews with employees. After analyzing the occupational accidents, therebar production process in the rolling unit was identified as a high-risk area. The HFACS checklist was usedto assess this process and classify the human factors contributing to accidents. Subsequently, DEMATELand ANP methods were applied to determine causal relationships and prioritize the factors.

Results: The HFACS analysis identified 236 human factors, among which the preconditions for unsafe actsand organizational factors had the highest frequency (24.57% each), while external factors had the lowest(8.47%). According to DEMATEL results, organizational influences exerted the greatest impact on otherlevels, whereas external factors had the least effect. In terms of being influenced by other levels, unsafeacts showed the highest level of susceptibility, whereas unsafe supervision had the lowest levels. Basedon ANP findings, the preconditions for unsafe acts had the highest importance, while unsafe supervisionhad the lowest in contributing to unsafe acts.

Conclusion: The findings of this study suggest that improving safety culture, improving organizationalregulations, implementing targeted training programs, and updating equipment can play a significantrole in reducing accidents caused by unsafe acts. The results provide practical insights for managers andpolicymakers and can serve as a useful tool for decision-making in occupational health and safety withinthe steel industry.