Accident risks in disturbance recovery in an automated batch‐production system

Accident risks in automated production systems occur mainly during system disturbance. However, few studies have dealt with this issue. We were able to investigate it by studying accident risks during the recovery of incidents occurring in the running of an automated bread production system in an industrial bakery. This problem was examined through worker interviews. The main results indicate that the accident risks associated with system disturbance are due to accessibility problems and the need to operate quickly to avoid production shutdowns or material damage. Different solutions have been implemented to reduce the disturbances and accident risks. The development of these solutions seems related to the managers' and operators' concepts of what constitutes a disturbance. © 2002 Wiley Periodicals, Inc.