Abstract
To err is an intrinsic human trait, which means that human errors, at some point, are inevitable. Business improvement tools and practices neglect to deal with the root causes of human error; hence, they ignore certain design considerations that could possibly prevent or minimise such errors from occurring. Recognising this gap, this paper seeks to conceptualise a model that incorporates cognitive science literature based on a mistake-proofing concept, thereby offering a deeper, more profound level of human error analysis. An exploratory case study involving an aerospace assembly line was conducted to gain insights into the model developed. The findings of the case study revealed four different causes of human errors, as follows: (i) description similarity error, (ii) capture errors, (iii) memory lapse errors, and (iv) interruptions. Based on this analysis, error-proofing measures have been proposed accordingly. This paper lays the foundation for future work on the psychology behind human errors in the aerospace industry and highlights the importance of understanding human errors to avoid quality issues and rework in production settings, where labour input is of paramount importance.