Oops, We Did It Again: Reducing Human Error-Induced Truck Unloading Events

Human error is a leading contributing factor to several well-known reactive chemistry and loss-of-containment events that involve unloading trucks to storage tanks or processing equipment. Driving, connecting hoses and initiating (and ending) chemical transfers requires worker actions that must be completed correctly in spite of these activities being done in an ever-changing work environment. Workers are faced with doing their jobs correctly in spite of personnel turnover, budget constraints, changes in technology, and organizational changes that sometimes add third parties (drivers, loaders, and operators) who may not understand the chemical, physical, or fire hazards of the job. Recent challenges brought by COVID-19 have added stressors and changes to the workplace that make it even more difficult to “get it right the first time.”

For decades, industry has been trying to reduce human error and unlock the mystery of why good employees make poor decisions that can create high-consequence events. Neuroscience research is identifying methods to implement human factor controls that reduce risk, and this information can be applied from the boardroom to the shop floor to improve the reliability of our operations. Critical organizational elements – including work environments, technological interfaces, operating procedures, training, work schedules and leadership actions – are often not aligned with how our brains work.

This presentation will provide:

1. An introduction to Brain-Centric hazards and how they led to process safety reactive chemistry and loss-of-containment events during truck unloading operations
2. Key Aspects and human factors that improve human performance based on new neuroscience research
3. Pragmatic actions and best practices companies are taking to reduce human error and improve reliability during truck unloading activities