This article presents methods of safety and reliability analysis based on systemic-structural activity theory, an alternative psychological framework to cognitive psychology. Systemic-structural activity theory understands human activity during task performance as a structured system of mental and motor actions and operations in which cognition, behavior and motivation are integrated by self-regulation mechanisms toward achieving a conscious goal. Systemic-structural activity theory methods of algorithmic, time-structure and complexity analysis incorporating the use of the MTM-1 (method-time measurement system) system to describe motor actions are demonstrated and discussed using the example of a small-serial production operation. These methods, which generate detailed models of human activity during task performance, are particularly useful at the early stages of the design and development process.