Unlock Human Reliability in complex Environments
Even in highly trained, regulated environments, human error remains a top cause of deviation, waste and compliance risk. But most organizations are addressing the wrong problem.
Human error isn’t a root cause — it’s a symptom.
Our Human Factors service helps you uncover what’s really behind recurring mistakes and redesign the system to work better with people, not against them.
Why Human Factors?
– Because Training isn't enough!
Most operational errors persist not because people don’t know what to do, but because the systems they work within create friction, confusion, or impossible expectations. Traditional CAPAs and root cause methods often miss this — and end up blaming individuals instead of fixing the system.
Common symptoms we help solve:
✅ Recurring “human error” deviations despite training
✅ High cost of rework and compliance actions
✅ Poor alignment between procedures and reality
✅ Low psychological safety and frontline engagement
✅ Managers unable to lead for performance under pressure
Our Human Factors service blends field observation, organizational psychology, and systems thinking to shift performance at the source. It includes:
Deviation Deep
Dive
We go beyond blame-based analysis and look for patterns, pressure points, and system design flaws hidden beneath the data.
→ Outcome: Clearer insight into error trends and more effective CAPAs.
Gemba-Based Field Observations
We conduct real-time “work as done” shadowing to identify gaps between procedures and reality.
→ Outcome: Actionable improvements based on how people actually work — not just how they’re supposed to.
Human Performance KPIs
We introduce tailored, predictive indicators like task complexity density or stress context frequency to help you see problems before they lead to deviations.
→ Outcome: Early detection of fragile processes and better performance forecasting.
Leadership Enablement
We equip your managers with tools to coach, not punish. Leaders learn how to shape culture, reduce fear, and improve reliability through smarter interactions.
→ Outcome: A stronger, safer, and more resilient team environment.
CLIENT STORY
In a tightly regulated pharmaceutical environment, one global manufacturer faced a recurring challenge: despite strong training programs, the same errors kept happening. Labelled as "human error," these issues led to rising deviations, waste, and low morale. The company partnered with us to look deeper—beyond training—into human factors, process design and organizational culture.
What we did
- On-site or remote discovery phase
- Analysis of deviation data and CAPAs
- Live gemba sessions with cross-functional teams
- Risk mapping and system design review
- Customized KPI development and dashboards
- Manager coaching and workshops
- Final action roadmap and support for implementation
Outcome in just 6 months!
- 28% reduction in “human error” deviations
- Improved CAPA accuracy and long-term impact
- Boost in psychological safety and team morale
- Managers coaching, not punishing
- Early identification of high-risk processes
“We realized we were penalizing what we didn’t understand. This work helped us see what was really happening and gave our managers the confidence to lead differently.”
Operations Director Italy
