Progressive Technologies for Preventing Unsafe Acts and Operator Errors

From Technical Reliability to Conscious Safety

The development of industrial safety management systems has reached a stage where technical solutions and management standards no longer provide a multiple reduction in injury rates. The center of gravity has shifted to the human — the operator, whose decisions in critical situations determine the outcome of the production process. In his presentation, Vitaly Dmitruk, drawing on 35 years of experience in the chemical industry and aviation engine manufacturing, analyzes the nature of unsafe acts by personnel and proposes a comprehensive approach to preventing them.

The speaker demonstrates that the vast majority of incidents are not related to equipment failures, but to the human factor: conscious violations, overconfidence of experienced employees, or loss of concentration under stress. Traditional briefings are not enough to solve these problems — tools are required that form stable reflexes and take into account the psychophysiological characteristics of workers.

VR Technologies: From Passive Listening to Muscle Memory

Based on Dale's Cone of Experience, the speaker notes the low efficiency of traditional lecture formats. For knowledge to turn into safe behavior skills, practical reinforcement is necessary. The use of virtual reality (VR) systems allows immersing the worker in a realistic production environment without risk to life and health.

The presentation details the mechanism of VR simulators using the example of practicing actions in case of electric shock. Scenarios allow not only testing the knowledge of the algorithm (how to properly approach the victim taking into account step voltage), but also simulating the factor of haste. An artificially created time deficit provokes errors, allowing the worker to "pretend" to face the fatal consequences of their actions. This effectively reduces unjustified overconfidence among experienced specialists and forms a reflex skill of avoiding danger.

Psychological Filters: Managing Internal Risks

In addition to training, a critically important element of error prevention is the assessment of the psychophysiological state of personnel. The speaker proposes the implementation of a multi-level filtration system that begins at the hiring stage.

First-Level Filter: Candidate Profiling

Not every specialist with a relevant diploma is capable of safely managing complex technological processes. The use of psychometric testing allows identifying individuals with inherent risks: a tendency to impulsive actions, absent-mindedness, or an inability to remain calm. Based on this data, decisions are made about admitting employees to high-risk work or transferring them to less critical areas.

Second-Level Filter: Pre-Shift Control

Even the most reliable worker can come to a shift in a state of deep stress, fatigue, or depression. The speaker emphasizes the importance of assessing situational tension before starting work. Line managers must be able to recognize signs of reduced concentration during pre-shift briefings and promptly suspend such employees from performing responsible tasks to eliminate the risk of an accident due to loss of attention.

What you will learn from this webinar:

• How to use VR simulators to develop reflex skills of safe behavior under stress and time pressure?
• What psychological characteristics of temperament must be considered when admitting operators to complex technological processes?
• How to implement a system of "psychological filters" to screen out candidates prone to risky behavior?
• How can you effectively combat the overconfidence of experienced workers without using penalties?
• How can a line manager recognize a dangerous psycho-emotional state of a subordinate before the start of a shift?