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Manufacturing companies around the world are under constant pressure to perform effectively and sustainably. Incidental processes, such as Quality Inspection (QI), are needed to achieve Zero-Defects Manufacturing (ZDM). This study aimed to identify the Human Factors and Ergonomics (HF&E) in the design of advanced automation, QI systems, and ZDM through selected papers and empirical observations. Our presented model is built around the six main dimensions, i.e., top management, manager (project owner), designers, engineers (internal and suppliers), and operators. The commitment of top management, the openness of the manager, the design-friendly nature of the technological system, and the constant updating of knowledge by engineers are important for the success of ZDM. Researchers need to be familiar with cognitive and organisational human factors to align theory with specific cases. Operators face physical and cognitive challenges, and their environment and health must be considered for their successful contribution to the design of advanced QI systems.