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This paper presents the initial framework adopted to assess human error in assembly tasks at a large manufacturing company in Ireland. The model to characterize and predict human error presented in this paper is linked conceptually to the model introduced by Rasch (1980), where the probability of a specified outcome is modelled as a logistic function of the difference between the person capacity and item difficulty. The model needs to be modified to take into account an outcome that is not dichotomous and feed into the interaction between two macro factors: (a) Task complexity: that summarises all factors contributing to physical and mental workload requirements for execution of a given operative task & (b) Human capability: that considered the skills, training and experience of the people facing the tasks, representing a synthesis of their physical and cognitive abilities to verify whether or not they are matching …