How to Improve Worker Safety While Cutting Costs in Manufacturing

Manufacturers are often tasked with improving worker safety while reducing operational costs. Finding the right balance between these two can be challenging.

With rising expenses and a competitive industry, cost-effective safety strategies are crucial. Investing in workplace safety protects employees while boosting productivity and reducing costly incidents.

In this article, we’ll explore practical approaches to improve safety standards without compromising the bottom line. Manufacturers can ensure both worker safety and cost efficiency by adopting the right tools, procedures, and mindset.

Streamline Safety Training Programs

Canadian Occupational Safety notes that 74% of businesses claim to have safety training, but many programs lack thoroughness. Only 59% of micro-businesses have implemented any safety training initiatives. This statistic highlights significant disparities in safety preparedness between small businesses and larger enterprises.

Effective training is essential for improving worker safety. Use digital resources to create efficient, cost-effective safety training programs. Virtual training modules and online courses may provide high-quality education for a fraction of the expense.

These systems may be customized to meet individual safety requirements and are simply updated as rules change. Employees can access training materials on-demand, reducing downtime and improving retention.

In-person training sessions can be supplemented with e-learning to minimize disruption while ensuring high engagement. Streamlining safety training allows businesses to save on resources while improving overall safety awareness and compliance.

What is the cost-effectiveness of online safety training?

Online safety training offers a cost-effective solution by reducing the need for in-person sessions. With digital tools, companies can train employees without logistical expenses like travel or venue bookings. Furthermore, online programs can be easily updated, ensuring compliance with minimal additional investment.

Implement Regular Safety Audits

Frequent safety audits are essential to identify potential hazards and prevent costly incidents. Conducting regular audits helps pinpoint areas that require improvement, such as equipment maintenance or safety protocols.

OSHA states that worker deaths in America have significantly dropped, from 38 deaths a day in 1970 to 15 in 2022. Worker injuries and illnesses have also decreased, from 10.9 incidents per 100 workers to 2.7. This progress is largely due to improved safety training and regular audits, enhancing workplace conditions.

To ensure consistent identification of risks and thorough audits, consider the following steps:

Use a checklist to standardize audits, ensuring all potential hazards are addressed.
Assign a dedicated safety officer or team to oversee and ensure audits are actionable.
Prioritize safety inspections to prevent costly emergency repairs and worker compensation claims.

Implementing audits as a routine part of operations helps reduce both direct and indirect costs related to workplace injuries. It also boosts employee confidence in safety protocols.

Who should be responsible for conducting safety audits?

A dedicated safety officer or team should conduct safety audits to ensure thoroughness and impartiality. They are trained to identify risks and provide actionable recommendations. Assigning responsibility to specific individuals ensures audits are not overlooked and that safety standards are maintained.

Invest in Cost-Effective Safety Equipment

Upgrading safety equipment doesn’t always mean spending large sums of money. Prioritize equipment that offers long-term value, such as ergonomic tools, protective gear, and safety guards. Researching cost-effective alternatives can provide similar protection without breaking the budget.

Aqueous film-forming foam (AFFF) is one such widely used tool for fire suppression in industrial and manufacturing settings. It effectively suppresses fires involving flammable liquids but poses serious health and environmental risks.

E.P. Fire mentions that water cannot extinguish liquid fires like gasoline because it sinks below the surface instead of smothering flames. Foam, with a lower density than fuel, stays on top and effectively puts out fires. Fluorosurfactants in AFFF make it particularly effective by repelling oils and fats, creating a unique firefighting solution.

However, the fluorosurfactants in AFFF are per- and polyfluoroalkyl substances (PFAS), which are long-lasting compounds that do not degrade quickly. These compounds are referred to as "forever chemicals" because they accumulate in both the environment and human bodies over time.

The Legal Fallout of AFFF Exposure

TorHoerman Law mentions that lawsuits have been filed by workers exposed to AFFF and by residents affected by contamination. Legal claims often allege negligence, lack of transparency, and failure to warn employees about AFFF dangers. These lawsuits result in costly settlements and damage the reputations of the companies involved.

On November 1, 2024, the Lawsuit Information Center reported that the court issued a new case management order for personal injury bellwether trials. It establishes critical timetables for discovery, expert witness disclosures, and trial preparation. This AFFF lawsuit update brings us closer to trial and a potential global AFFF settlement before the first hearing begins.

Many manufacturers are now searching for safer fire suppression alternatives to avoid legal and financial repercussions. Transitioning away from AFFF can reduce potential lawsuits and minimize long-term environmental liability for manufacturers.

What are the long-term financial implications of AFFF lawsuits?

Long-term financial implications of AFFF lawsuits include legal fees, compensation claims, and environmental cleanup costs. Settlements could amount to millions of dollars, affecting cash flow and profits. In the long run, these lawsuits can diminish a company’s financial stability and market standing.

Foster a Safety Culture Among Workers

Creating a safety culture within the workforce is one of the most cost-effective methods for improving workplace safety. Encourage employees to be responsible for their own and others' safety.

Recognize and reward safe actions to highlight the significance of workplace safety. Regularly hold safety meetings to discuss new challenges, share ideas, and review potential risks. Open communication between workers and management helps identify safety concerns early and encourages collaboration.

Workers will be more vigilant in spotting hazards and following protocols by fostering a proactive safety mindset. This can reduce incidents and improve morale.

How can employee safety responsibility reduce incidents?

When employees take responsibility for their own and others’ safety, they become more vigilant. This proactive mindset helps workers spot hazards early and take corrective actions before accidents occur. A culture of shared responsibility lowers the risk of incidents and fosters safer work environments.

Improving worker safety can be costly, but smart investments offer long-term savings for manufacturers. Prioritizing safety training, conducting frequent audits, and using low-cost equipment all contribute to a safer and more efficient workplace. When employees can detect and handle problems, the safety culture improves for everyone.

Safety programs not only reduce incidents but also improve operational efficiency. A strong safety culture encourages proactive risk management and boosts employee morale. Investing in safety benefits both workers and the company’s bottom line. Ultimately, these efforts contribute to a safer workplace and better financial health, making safety an essential part of long-term success.