Development of a Risk-Based Maintenance Framework for Improving Human Reliability in Disc Brake Maintenance Using the HEART Method

Deded  Alhabib; Humiras  Hardi Purba

doi:10.31181/sa202574

Authors

Deded Alhabib Department of Industrial Engineering, Mercu Buana University, Jakarta, Indonesia. Author
Humiras Hardi Purba Department of Industrial Engineering, Mercu Buana University, Jakarta, Indonesia. Author https://orcid.org/0000-0002-8166-6845

DOI:

https://doi.org/10.31181/sa202574

Abstract

Disc brake maintenance is a critical activity in ensuring the safety and reliability of passenger vehicles. In vocational automotive workshop environments, maintenance activities are vulnerable to human error due to limited operator experience, time pressure, and inadequate work procedures. This study aims to develop a Risk-Based Maintenance (RBM) framework for improving human reliability in disc brake maintenance using the Human Error Assessment and Reduction Technique (HEART) method. The research employed a mixed-methods approach with a sequential explanatory design. Quantitative analysis was conducted through Hierarchical Task Analysis (HTA), Generic Task Type (GTT) classification, identification of Error Producing Conditions (EPCs), Assessed Proportion of Effect (APOE) evaluation, and Human Error Probability (HEP) calculation. Qualitative data were collected through observations, interviews, and Focus Group Discussions involving vocational instructors and automotive technicians. The results showed that initial inspection (HEP = 2.49), brake disc inspection (HEP = 2.48), and brake pad and caliper reassembly (HEP = 1.81) were identified as the most critical maintenance activities. The dominant EPCs included time pressure, limited operator experience, poor work procedure quality, and the absence of independent checking. Based on these findings, an RBM framework was developed to prioritize risk control actions through improved supervision, enhanced practical training, refinement of standard operating procedures, and implementation of independent inspection mechanisms. The proposed framework integrates HEART-based human reliability assessment with Risk-Based Maintenance principles to support systematic maintenance risk control and human reliability improvement in vocational automotive workshop environments.

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