A boiler is one of the critical systems in various industries even in the food industry. The cost of boiler maintenance including repair and replacement are very high. Therefore, options such as fitness for service are used as cost effective measures to demonstrate the performance characteristic of a component that might be operating with a flaw. This option is prone to a number of avoidable human errors like other maintenance functions. This paper aims to identify and examine the human factors acting as barriers for successful performance of fitness for service assessments in a boiler. It further recommends the possible solutions for the reduction and avoidance of reoccurrence of human errors. A single exemplary case study of a boiler in an anonymous company was selected. The study adopted a documentation review and observation as data collection tools to examine the source of human errors. Human errors such as wrong and insufficient measurements, poor work planning, and improper data collection and recording were identified as key barriers for successful performance of fitness for service assessments of a boiler system. The study further revealed that human factors such as lack of experience and training, poor communication and organizational practices are key causal factors.

Keywords:

Boiler, fitness for service, flaw, human factor, human error.