11 Ways To Reduce Accidents In The Manufacturing Industry

Accidents in the manufacturing industry can be fatal and cost businesses thousands of dollars. Thankfully, there are many ways to reduce the risk of accidents in manufacturing, from establishing safety protocols to investing in technology. Although it requires time and effort, businesses must take proactive steps to protect their employees and keep their operations running smoothly.

From investing in employee training to performing regular Gemba walks, businesses can make sure that their employees are safe and minimize the risks associated with operating a factory or a manufacturing facility. In this article, we share industry expert tips to help you minimize the risk of costly and dangerous accidents in the workplace.


Best Practices To Optimize Safety And Health At Work In The Manufacturing Industry

1. Establish A Strong Safety Culture

Establishing a strong safety culture in the manufacturing industry is essential to reduce accidents. Properly training employees on safety protocols as well as providing adequate safety equipment is necessary to ensure everyone’s health and well-being. That being said, it’s not enough just to provide the tools, you also have to make sure that safety practices are followed strictly.

Occupational safety and health should be a priority for all manufacturing organizations. Enforcing proper safety measures can greatly reduce the risk of accidents, which could otherwise lead to serious injury or death. Safety-related policies should also be reviewed regularly to ensure that they are up-to-date with industry standards. Training must be provided regularly so that everyone is familiar with the company’s expectations and procedures in order to create an effective culture of safe work practices.

What is safety in the manufacturing industry?


2. Provide Adequate Training

Adequate employee training is an essential part of reducing accidents in the manufacturing industry. From safety hazards to protective equipment, every aspect of workplace safety must be addressed in order to reduce the likelihood of work-related injuries. When employees are equipped with the knowledge and tools they need to do their job safely, they become more confident in their ability to maximize productivity while minimizing risk.

For manufacturers looking to reduce the number of accidents on their premises, providing adequate training should be a priority. Employees should have a comprehensive understanding of safety procedures involving machines and heavy equipment, as well as understand how to properly use protective gear like gloves, goggles, and clothing. Additionally, workers should be able to identify potential hazards and know how to take steps to prevent them from becoming dangerous issues.

Manufacturers that offer regular safety seminars or workshops for their employees can help ensure that everyone is aware of both general safety rules and specific procedures for each task. It’s also important for employers to consider providing refresher courses throughout the year so that workers stay up-to-date on safety protocols and regulations.


3. Create Clear Policies And Procedures

Manufacturing companies should create clear policies and procedures that are rigorously followed by workers. This is more than just a matter of following industry regulations, it’s about creating an environment in which employees feel safe enough to speak up when they spot something potentially hazardous. This is especially important in manufacturing plants where the use of heavy machinery can cause serious injury if not handled properly.

Communication is key to making sure everyone knows what is expected of them, which is why it’s important to have a system in place that ensures all new policies or changes are quickly shared with staff. This can include regular emails or meetings, but there should also be a way for employees to ask questions about anything they don’t understand or need more information on. Ultimately, this will create an atmosphere of trust between management and workers which will lead to fewer accidents in the workplace.


4. Implement Automation And Robotics

In order to reduce the number of accidents in the workplace, it’s important to consider how advances in automation and robotics can help create a safer environment for workers. Robotic safety interventions can be especially useful to prevent slip and fall accidents, one of the most common causes of occupational injuries. Robots are able to identify potential hazards more quickly than human workers could, allowing them to take action before accidents occur.

Automated systems can also monitor hazardous areas and alert workers if they enter a dangerous zone. This helps to reduce the risk of injury from hazardous materials or equipment that may have been overlooked by human workers.  By implementing automation and robotics into manufacturing processes, companies can improve their safety management systems and reduce the risk of accidents on the job.

Safety walk vs. Gemba walk


5. Promote Ergonomic Practices

Ergonomic practices are an essential part of keeping employees safe and healthy. Ergonomics focuses on the interaction between people and their environment and can be used to reduce the risk of employee injuries and other potential risks. Good ergonomic practices can range from specific equipment designed for comfort and safety (like adjustable chairs or keyboards) to changes in how workers interact with machines or materials.

For example, when working with heavy machinery or materials, providing a ramp or lift assist can help reduce the strain on workers’ backs. Providing tools that are designed for comfort can help reduce arm and wrist strain due to repetitive motion tasks. In addition to physical support, providing workers with regular breaks can help reduce fatigue-related errors or accidents.

Creating a culture where workplace safety is encouraged is also important to promote ergonomic practices in manufacturing settings. Encouraging open dialogue about potential risks can help identify areas where injury risk may be higher. Regular training sessions on ergonomics and safety protocols should also be incorporated into a successful safety program to ensure that all employees have the latest information on best practices to reduce workplace injuries.


6. Maintain Equipment And Machinery

No one wants to be the person responsible for a work-related accident, especially in the manufacturing sector. That’s why it’s so important to maintain equipment and machinery that is used in manufacturing and construction sites. Proper maintenance can help reduce the chances of fatal accidents, especially when working with flammable materials or hazardous materials.

When machines aren’t properly maintained, they become more prone to breakdowns and malfunctions, which can lead to work-related injuries or death. It’s essential that employees receive proper training on how to use and maintain the equipment they are operating. This includes regularly checking the safety features of the machine, such as emergency stop buttons, interlocks, and guards, as well as ensuring all components are functioning properly before use. Regular maintenance checks should also be conducted on a regular basis.

In addition to regular checks and maintenance, business owners should invest in good quality protective gear for manufacturing workers. This includes gloves, goggles, helmets, respirators, and other protective items such as flame-retardant clothing. By equipping their employees with the right safety gear, manufacturers can further reduce the likelihood of accidents occurring in their facilities.

7 effective cost saving ideas for manufacturing companies


7. Monitor For Hazards Regularly

Monitoring for hazards regularly is essential to reduce accidents in the manufacturing industry. The potential risks of slips, trips, and falls are especially common and must be identified in order to ensure a safe working environment. According to the Health and Safety Executive (HSE), investing in regular monitoring of hazards can prevent an estimated 60% of all accidents that occur in manufacturing environments. Companies should invest time and resources into creating a comprehensive risk assessment plan that identifies any existing or potential threats to employee health and safety.


8. Invest In Personal Protective Equipment

Personal protective equipment (PPE) refers to items used by workers to protect themselves from hazardous conditions in the workplace. These items can range from safety goggles and face shields to helmets and gloves. Even something as simple as a hard hat can make a huge difference when it comes to preventing accidents at a manufacturing site. Safety protocols should also be established so that workers know how and when these items should be worn.

In addition, employers must be prepared for any potential accidents that may occur despite the use of personal protective equipment. They should have adequate procedures in place for responding quickly and effectively if an accident takes place. Training sessions should be provided so that employees are aware of the dangers they could face in their workplace and know how to best respond to them.


9. Implement Quality Control Measures

Quality control measures can help reduce the likelihood of accidents occurring on the factory floor. They involve monitoring processes and ensuring that safety protocols are being followed at all times. Quality control measures also involve regularly inspecting equipment to identify any potential problems before they become more serious. By implementing quality control measures, manufacturers can focus on prevention rather than reaction when it comes to ensuring a safe environment for their workers.

How to improve your business with Gemba Walk


10. Perform Risk Assessments

By looking ahead and breaking down tasks into smaller steps, risk assessments can help identify possible problems before they occur. This allows for proactive solutions to be put in place. These solutions might include redesigning certain tools or processes, adding safety equipment, or training personnel on the proper use of tools or machines.

It may even mean changing the physical layout of the environment to reduce the potential for accidents. Risk assessments can help prevent costly mistakes and protect workers from avoidable harm. They provide an overview of what needs to be done and allow businesses to identify areas where improved safety measures are needed.


11. Perform Safety Gemba Walks

The workplace can be a dangerous place. When it comes to manufacturing, the risk of nonfatal injuries and fatalities is high. That’s why it’s important to take proactive steps to reduce danger in the workplace. One such step is performing Gemba walks, which involves inspecting the environment for potential safety risks and hazards.

Gemba walks give supervisors and managers an opportunity to observe how workers interact with each other, as well as how they use their tools and equipment. This helps them identify potential problems that could lead to workplace accidents or injuries. It also allows them to make sure that proper safety equipment is being used by employees and that workers are adhering to the safety policies and procedures put in place by the company.

Digitize your Gemba Walks