Journal of Product Design, Quality Engineering & Technology

Abstract

Human error remains one of the most persistent contributors to accidents, quality failures, and inefficiencies across industrial systems. Traditional safety approaches often rely on training, procedures, and post-incident corrective actions, which may not adequately address the root causes of human error. Prevention in Design (PtD) offers a proactive approach by integrating safety, usability, and error prevention strategies directly into the design phase of products, processes, and systems. This review paper examines the role of PtD in reducing human error by focusing on design-based prevention rather than behavioral correction. The paper discusses theoretical foundations of human error, classifications of error types, and the evolution of PtD principles. Key design strategies such as error-proofing, ergonomics, human-centered design, and system simplification are analyzed. Industrial case examples from manufacturing, healthcare, construction, and transportation sectors are reviewed to demonstrate practical implementation. Challenges, limitations, and future research directions related to digital design tools and Industry 4.0 integration are also discussed. The study concludes that human error reduction through PtD is not only feasible but essential for achieving sustainable safety and quality performance in complex socio-technical systems.

Keywords: Human error, Prevention in Design, PtD, error-proofing, human-centered design, safety engineering