PurposeThis study deals with the reliability analysis of a hybrid series–parallel system consisting of two subsystems A and B with two human operators. Subsystem A has two units in active parallel while subsystem B consists of two-out-of-four units. Both units have exponential failure and repair time. The system under consideration has two states: partial failure state and complete failure state. The mathematical equations associated with the transition diagram have been formulated using regenerative point techniques. The system is analysed using Laplace transforms to solve the mathematical equations. Some important measures of reliability such as availability of system, reliability of the system, mean time to failure (MTTF), sensitivity for MTTF and cost analysis have been discussed. Some particular cases have also been derived and examined to see the practical effect of the model. The computed results are demonstrated by tables and graphs. Furthermore, the results of the designed model are beneficial for system engineers and designers, reliability and maintenance managers.Design/methodology/approachThis paper considered a hybrid series–parallel system consisting of two subsystems A and B with two human operators. The performance of the system is studied using the supplementary variable technique and Laplace transforms. The various measures of reliability such as availability, reliability, mean time to system failure (MTSF), sensitivity for MTTF and cost analysis have been computed for various values of failure and repair rates. Maple 13 software has been used for computations.FindingsIn this research paper, the authors have computed various measures of reliability such as availability, reliability, MTSF, sensitivity for MTTF and cost analysis for various values of failure and repair rates and find that failure due to human operators are more responsible for successful operation of the system and also regular repair should be invoked to improve system performance.Originality/valueThis research paper is the original work of authors. The references are well cited based on the importance of study. Nothing has been detached from any research paper or books.