An Integrated Fuzzy Delphi and Fuzzy AHP Model for Evaluating Factors Affecting Human Errors in Manual Assembly Processes

Human errors (HEs) are prevalent issues in manual assembly, leading to product defects and increased costs. Understanding and knowing the factors influencing human errors in manual assembly processes is essential for improving product quality and efficiency. This study aims to determine and rank factors influencing HEs in manual assembly processes based on expert judgments. To achieve this objective, an integrated model was developed using two multi-criteria decision-making (MCDM) techniques—specifically, the fuzzy Delphi Method (FDM) and the fuzzy Analytic Hierarchy Process (FAHP). Firstly, two rounds of the FDM were conducted to identify and categorize the primary factors contributing to HEs in manual assembly. Expert consensus with at least 75% agreement determined that 27 factors with influence scores of 0.7 or higher significantly impact HEs in these processes. After that, the priorities of the 27 influencing factors in assembly HEs were determined using a third round of the FAHP method. Data analysis was performed using SPSS 22.0 to evaluate the reliability and normality of the survey responses. This study has divided the affecting factors on assembly HEs into two levels: level 1, called main factors, and level 2, called sub-factors. Based on the final measured weights for level 1, the proposed model estimation results revealed that the most influential factors on HEs in a manual assembly are the individual factor, followed by the tool factor and the task factor. For level 2, the model results showed a lack of experience, poor instructions and procedures, and misunderstanding as the most critical factors influencing manual assembly errors. Sensitivity analysis was performed to determine how changes in model inputs or parameters affect final decisions to ensure reliable and practical results. The findings of this study provide valuable insights to help organizations develop effective strategies for reducing worker errors in manual assembly. Identifying the key and root factors contributing to assembly errors, this research offers a solid foundation for enhancing the overall quality of final products.