The prevention of work-related/occupational incidents and accidents caused by human error in the South African automotive manufacturing industry

Abstract

The purpose of this study was to examine how work-related incidents and accidents caused by human error can be prevented in the South African automotive manufacturing industry, a sector that contributes significantly to the economy but remains vulnerable to occupational injuries and operational disruptions. The study further aimed to develop a practical framework to strengthen safety management and reduce the recurrence of human error. A qualitative research approach was adopted within an interpretivist paradigm. Thirteen participants drawn from management and employees in an automotive organisation were interviewed through semi-structured and face-to-face interviews. Thematic analysis, supported by ATLAS.ti software, was used to identify recurring patterns, perceptions, and experiences of safety practices. The findings revealed that human error incidents arise from multiple, interconnected factors, including inadequate training, fatigue, poor communication, insufficient supervision, limited organisational accountability, and gaps in safety management systems. These results underscore that fragmented interventions are insufficient; effective prevention requires an integrated approach that combines technical controls, behavioural strategies, and strong organisational leadership. In response, the study developed the Human Error Incidents Prevention Framework (HEIPF), which integrates internal and external factors, decision-making processes, workplace conditions, and employee involvement to reduce error-related incidents. The framework contributes to strengthening safety culture, improving employee well-being, enhancing operational efficiency, and increasing profitability. Theoretically, the study advances knowledge of the interplay between human, organisational, and technical factors in occupational safety, while it offers the automotive industry an adaptable, evidence-based framework for reducing human error in high-risk environments. Ultimately, this study demonstrates that the prevention of human error in the automotive manufacturing industry is not only a compliance requirement but also a strategic enabler of safety, productivity, and long-term organisational sustainability.