Human error is a common challenge in manufacturing that can lead to costly mistakes, production delays, and even safety hazards. Despite the use of advanced technology and automation, the human element remains integral to manufacturing processes, and errors are an inevitable part of any system involving people. Understanding the causes and types of human errors is crucial for developing strategies to reduce their occurrence and impact. In this blog, discuss practical solutions to minimize these errors.

What is Human Error in Manufacturing?

Human error refers to mistakes made by workers during the manufacturing process. These errors can occur for various reasons, including lack of training, miscommunication, fatigue, or unclear instructions. In a manufacturing environment, even minor errors can lead to defective products, production delays, and increased costs. Recognizing that human error is often a symptom of underlying issues rather than the cause itself is the first step toward effectively reducing it.

Types of Human Error in Manufacturing and their Impact

1. Slips and Lapses:

Slips and lapses are unintentional errors that occur when a person’s attention or memory fails them during a task. 

Impact on Manufacturing:

Slips and lapses can lead to minor defects that might not be immediately noticeable but can accumulate over time, resulting in significant quality issues. They can also cause rework, delays, and increased costs if the errors are caught later in the production process.

2. Mistakes:

Mistakes are errors in decision-making or judgment that occur when a person’s knowledge or understanding is insufficient or incorrect. Unlike slips and lapses, which are execution errors, mistakes are errors in planning. Mistakes can happen when a worker is unsure of the correct procedure, misinterprets instructions, or makes an incorrect assumption about the best course of action.

Impact on Manufacturing:

Mistakes can have a significant impact, potentially leading to widespread defects, production downtime, or even safety incidents if critical procedures are not followed correctly. They often require extensive rework, waste valuable materials, and can delay production schedules.

3. Violations:

Violations are deliberate deviations from established procedures, rules, or standards. These errors occur when a worker knowingly decides to bypass standard operating procedures, often due to perceived time constraints, inefficiency in the prescribed method, or overconfidence in their abilities. Violations can be particularly problematic because they are intentional, often stemming from a belief that the deviation will not result in harm or that the established procedure is unnecessary.

Impact on Manufacturing:

Violations can lead to severe consequences, including safety incidents, equipment damage, and major product defects. Since these actions are intentional, they can be more difficult to detect and correct, potentially leading to a culture of non-compliance if not addressed promptly.

Strategies to Overcome Human Error in Manufacturing

1. Implementing Standardized Work Instructions:

One of the most effective ways to reduce human error is by standardizing work instructions. Clear, detailed instructions ensure that every worker follows the same procedures, reducing variability and mistakes. 

Digital Standard Work Instruction tools like Standard Work Pro allow manufacturers to create visual work instructions that include images, diagrams, and videos, guiding workers step-by-step through each process. This approach helps to minimize slips and lapses by providing a visual reference that workers can easily follow.

2. Enhancing Training and Skill Development:

Comprehensive training programs are essential to ensuring that workers have the knowledge and skills needed to perform their tasks correctly. These programs should cover both technical skills and the importance of following procedures to prevent errors. By regularly updating training programs and offering refresher courses, you can reduce mistakes caused by a lack of knowledge or outdated practices.

3. Utilizing Error-Proofing Techniques (Poka-Yoke)

Error-proofing, or Poka-Yoke, is a proactive approach to preventing errors by designing processes that make it difficult or impossible for mistakes to occur. This can involve physical devices that prevent incorrect actions or digital systems that alert workers to potential errors. 

For example, Mistake-Proofing Software can be used to set up automated checks and alerts during the production process, ensuring that errors are caught before they lead to defects. This approach is particularly effective in reducing mistakes and violations by creating an environment where the correct action is the only option.

4. Improving Communication and Information Sharing:

Effective communication is crucial in preventing errors, especially in complex manufacturing environments where multiple teams are involved. Miscommunication can lead to misunderstandings and mistakes. Some Smart factory software tools facilitate real-time communication, enabling workers to share information, ask questions, and clarify instructions quickly. By ensuring that everyone has access to the same information and can communicate easily, you reduce the likelihood of errors caused by miscommunication or missing information.

5. Implementing Real-Time Monitoring and Feedback:

Real-time monitoring systems allow manufacturers to track production processes as they happen, identifying deviations from standard procedures and correcting them immediately. Systems like SCADA (Supervisory Control and Data Acquisition) or MES (Manufacturing Execution Systems) provide real-time data on production performance, alerting managers to potential issues before they escalate. This immediate feedback helps to catch slips, lapses, and violations as they occur, reducing their impact on the overall production process.

6. Designing Ergonomic Workspaces:

An ergonomic workspace reduces physical strain on workers, which can lead to fatigue and errors. By designing workstations that are comfortable and support proper posture, manufacturers can help prevent errors caused by physical discomfort or fatigue. Ergonomic Assessment Tools can be used to evaluate and optimize workspaces, ensuring that they are suited to the tasks being performed. 

For example: Adjustable workbenches, anti-fatigue mats, and supportive seating can all contribute to a more ergonomic environment, reducing the likelihood of errors.

7. Promoting a Culture of Continuous Improvement:

Encouraging a culture of continuous improvement empowers workers to identify potential issues and suggest improvements to processes. This proactive approach helps to catch errors before they occur and fosters a sense of ownership among employees. Tools like Kaizen Software allow workers to submit suggestions, track progress, and implement changes. By involving employees in the improvement process, you create an environment where errors are seen as opportunities for learning and development, leading to ongoing reductions in human error.

Role of Digital Tools and Systems in Human Error Reduction

In modern manufacturing, reducing human error isn’t just about better training—it’s about smarter systems. Digital factory software helps standardize execution, track mistakes, and alert teams in real-time. Tools like Solvonext, a structured problem solving software, ensure consistent root cause analysis (RCA) and faster issue resolution. Built-in escalation workflows help flag problems before they snowball, while digital SOPs eliminate ambiguity and keep teams aligned.

These platforms also act as software to detect human error trends—highlighting recurring slips, lapses, or violations across shifts or locations. By embedding RCA software into daily routines, manufacturers create a closed-loop system where errors lead to action, not just discussion. The result? Fewer defects, faster corrections, and a more accountable frontline workforce.

Conclusion

While human error can’t be eliminated, it can be controlled, reduced, and learned from—if the right systems are in place. Solvonext transforms your factory into a digitally disciplined environment where every issue is tracked, analyzed, and resolved using built-in problem solving software, digital SOPs, and RCA tools. It gives supervisors real-time visibility and frontline workers a clear, structured way to escalate and act—reducing guesswork and repeat errors.

If you're serious about building a culture of continuous improvement and minimizing costly human mistakes, it's time to see Solvonext in action.

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FAQs on Human Error in Manufacturing

Can software actually detect human errors?

Yes, problem solving software and RCA tools can identify trends, missed steps, and recurring mistakes through real-time data and structured workflows.

How do digital SOPs reduce human error?

They provide clear, visual instructions that are easy to follow, reducing guesswork and standardizing task execution across operators.

Can human error impact quality KPIs like OEE?

Absolutely. Errors lead to rework, downtime, and defects—all of which lower OEE and increase the cost of quality.

Is Poka-Yoke still relevant in digital factories?

Yes—error-proofing is even more powerful when combined with real-time alerts and digital enforcement of standard work.

How can we track human error trends across shifts?

Use a digital escalation system that logs, categorizes, and timestamps every incident—so patterns become visible over time.

What if workers resist using digital tools?

Start with simple interfaces, highlight time savings, and get early buy-in—Solvonext is designed for blue-collar usability.

How does Solvonext reduce human errors?

By enforcing structured RCA, tracking each problem's lifecycle, and enabling real-time escalation with digital SOPs and accountability tools.