Human Factors in Control Room Operations in Mineral Processing

Abstract

This study applied human factors research approaches to the complex and dynamic environment of mineral processing plants. In this domain, little formal human factors research has previously been undertaken, despite that human performance limitations are frequently noted as a bottleneck to effective production. This article presents a broad, operator-centered investigation on the current status of control room operations and explores the underlying barriers in the operators’ work environment. A total of 20 operators working at two types of Australian mineral processing plants were involved. Multiple data collection methods, including in situ observations and interviews, surveys, and reviews of documentation, were used. The findings revealed that operator control was essentially in a reactive mode, with operators often lacking the will or ability to engage in process optimization. A simplified work domain analysis was used to highlight the essential elements involved in operator control and to explore the gaps between the observed reactive behavior and the required proactive control employed by operators. Also, this study uncovered deficiencies in the current information and organizational environments constraining operator control ability. These deficiencies included poorly designed human-machine interface and alarms, insufficient operator training, and inappropriate task allocations. Further research for enhancing operator capacity is recommended and highlighted.