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Running head: SAFETY IN MANUFACTURING 1

SAFETY IN MANUFACTURING 10

Safety in Manufacturing

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Abstract

The manufacturing sector is facing different aspects of hazards. The workplace is supposed to be safe enough for the employee. This is the reason why the OSHA standards are provided to give a framework for all the activities that must be done to enhance safety. Some of the risks that the employees are exposed to include; the risk of injuries which in some cases can turn fatal. The workplace has the equipment, chemicals as well as heights which can turn disastrous. Therefore, implementing safety standards will enhance safety. The employees feel safe and motivated and hence increase productivity. Some risks include noise, vibrations, and exposure to hazardous chemicals. The manufacturing industry should thus involve the employees in the safety processes and ensure that they have policies and regulations that enhance safety. Therefore, implementing occupational safety and health practices enhances safety operations in the manufacturing sector.

Keywords

Workplace safety, OSHA, Workplace injuries, workplace risks

Introduction

Manufacturing is the process that is used to change the raw materials into a finished product. The process uses machinery and equipment to enhance the speed of manufacturing and the quality of the products. During the manufacturing process, workplace accidents can happen. It leads to losses of billions of dollars each year. The employees have a right to work in a safe environment. This is the reason why there are safety and health practices which are provided in every manufacturing facility. Adopting safety practices is likely to reduce the chances of accidents (Abraham & Rabin, 2019). Most of the cases reported are due to a lack of knowledge on the part of the employees or lack of training. Therefore, it is important to understand the safety practices in the workplace and the benefits they present.

Problems such as workplace accidents, illnesses, and diseases are a big problem in manufacturing. There is a general lack of safety consciousness although there are laws and regulations and policies put in place. According to Yang and Jeong, the number of accidents reported in the manufacturing industry is higher than the others (2019). Different countries report varying cases of either fatal or non-fatal accidents in the manufacturing setup. Figure 1 shows the variation in statistics of the accidents in the European Union.

Figure 1: Accidents in Manufacturing Setup

Statistics on Manufacturing

Organizations and companies have put the best safety efforts in manufacturing activities. However, despite such efforts, accidents are still occurring. In the year 2018, the Occupational Safety and Health Administration levied $50 million in fines to the companies which were violating the safety regulations (Viscusi,n 2018). This is the body that requires that the manufacturing setup is designed in a manner that helps to keep the workers safe. Ensuring a safe work environment is beneficial because it helps to comply with OSHA requirements and at the same time keep the employees motivated and focused on their work.

Safety Issues in Manufacturing

Different safety issues arise in the manufacturing industry

Hazard Communication Standard

In any given manufacturing industry, it is a requirement that information concerning the different hazardous chemicals is obtained and documented (Oah, Na & Moon, 2018). OSHA provides that such chemicals should be classified and labeled as well as providing the right training to the employees.

Respiratory Protection

It is a requirement that the employees are provided with respiratory protection when they are in contact with harmful contaminants (Oah, Na & Moon, 2018). These can be gases or vapors that may cause diseases and problems such as lung impairment or even death.

Lockout

It is possible that as the employees are working, they may encounter some electrical or mechanical faults. These are a serious threat to the wellbeing of the workers and can lead to serious injuries or death. Therefore, it is important to use the lockout to determine how the energy is released as well as disabling the machine to prevent the occurrence of accidental releases.

Powered Industrial Trucks

These are the machinery that is used in moving materials during the manufacturing process. Although they seem harmless, they can cause harm especially when the materials are transported and they fall.

Importance of Safety in Manufacturing

Maintaining safety during the manufacturing process is important because it is a way of preventing the risks of workplace injury. According to Tortorella and Fettermann, there is a rise in the productivity levels when the manufacturing companies implement safety standards (2018). This is because the employees are confident and they know that they are safe and hence the probability of having a life-threatening accident is reduced. They are thus motivated to give the best in all the operations. The OSHA standards seem to be overwhelming to many manufacturing companies. However, they are important in enhancing proactive approaches to the safety of their employees. With proper compliance, the companies can avoid fines, workers' compensation, recovery costs, and damage to reputation (Wiengarten et al., 2017). Figure 2 shows the conceptual framework that companies should use in injury management in manufacturing.

Figure 2: Conceptual Framework in Injury Management

Consequences of not Adopting Safety Measures in Manufacturing

The manufacturers are required under the law to implement different safety standards. However, when they do not, they are subjected to heavy fines and penalties. At the same time, when OSHA identifies the companies which are in deviance with the established safety standards, they publish their names (Sirilertsuwan, Hjelmgren&Ekwall, 2019). This is one approach that can damage the reputation of the organizations. Apart from the negative reputation, when the employees are injured in the workplace, they are entitled to compensation and medical treatment costs. The loss the company incurs is high because they have to train a new employee while at the same time taking care of the injured one. According to Sirilertsuwan, Hjelmgren, and Ekwall, as of 2016, the manufacturing industry incurred $32,000 in medical bills for workplace injuries and the cost per death in the workplace was $1,120,000(2019). The other impact of workplace injuries is that it affects the other employees emotionally and hence making them less prepared to take any risks that can lead to injuries or death.

OSHA Safety Requirements

OSHA provides several standards to be implemented in the manufacturing industry to prevent and avoid the occurrence of risks. These procedures must be inspected by a team of experts who ascertain that the company or firm is up-to-date with the standards (Park, Johnson & Hong, 2020). These standards vary depending on the activities carried out in a firm. Some of these standards include;

Hazard Communication Standard

Every manufacturing firm is required to have a hazard communication plan that is used to educate the employees on the hazardous chemicals and the threats they pose in their lives.

Emergency Action Plan

The emergency action plan is a clear definition of the steps that the employees in the workplace must undertake when there is an emergency or when an accident such as a fire occurs.

Fire Prevention Plan

The fire prevention plan is put in place to address the issues of fire safety for all the employees in the firm (Park, Johnson & Hong, 2020). It also evaluates the possible fire hazards that can occur in the organization.

Exit Routes

Every manufacturing company must ensure that they provide the exit routes that are in line with the OSHA standards. The workplace must have at least two exit routes so that the evacuation of the employees and other occupants is easier in case of an emergency (Park, Johnson & Hong, 2020).

Personal Fall Protection Systems

OSHA provides that the major cause of workplace injuries and fatalities is falling from heights (Li et al., 2020). Therefore, it is important to provide the employees with protective equipment such as helmets so that they are not injured. At the same time, the workplace should include the right working height.

Safety and Health Practices in Manufacturing

Many firms in the manufacturing industry pay attention to the issues of occupational safety and performance because it influences the levels of productivity. However, there is a challenge in meeting and maintaining the established standards (Li et al., 2020). However, it is important to prevent injuries because they reduce worker morale and keep them suffering personally from such accidents. Some of the methods of enhancing safety in the manufacturing workplace include;

Training

Training is the process of making the employees understand the hazards that can be encountered in the workplace and how they can be avoided and mitigated. The employees become productive in a safe workplace. According to Loosemore and Malouf, workplace injuries and accidents increase whenever the training is ineffective(2019). Therefore, the employees must understand the goals, tasks as well as strategies that must be used. This makes the process very complex although the employer must fulfill their responsibility of enhancing employee safety. The employees are also supposed to have supervision when it comes to safety and control from the injuries.

Safe Work procedures

Every manufacturing process has some procedures that must be followed. The employees must follow safe work procedures so that their safety is enhanced and injuries and accidents are prevented. Therefore, the best approach for a manufacturing setup is to implement and comply with all the safety and health procedures and standards to prevent accidents. According to Harsini et al., accidents in the workplace can be managed if the employees can deal with the issue of human error (2020). As a result, a positive attitude to safety is one way of preventing accidents. Employees should use safe work procedures to reduce fatalities and accidents.

Consultation

Consultation is the process of seeking clarity or more information when the employees are not aware of what to do. The main reason why consultation is important is that it helps to prevent human error in the manufacturing process. Organizations can encourage consultation by holding employees responsible when accidents occur. However, consultation is determined by the relationship between the management and the employees. With a good relationship, the employees are likely to ask for clarity whenever a need arises. Good communication also enhances consultation. According to Gembalska-Kwiecień et al., the employees have a right to participate in safety and health matters (2018). They are free to give their opinion and suggestions on how safety within the workplace can be improved.

Safety Reporting

Safety reporting is giving an internal report on the safety status within the organization. It includes the people who make the reports using the information received from the employees. Safety reporting in the manufacturing industry is important because the management receives the right information on the problems of safety that are hindering productivity. They can, therefore, come up with the measures of curbing these problems and enhance safety in the workplace. According to Tucker, Ogunfowora, and Ehr, the gender of the employees influences the reporting on safety in the organization(2016). The young male employees are less likely to communicate in safety matters compared to the young female workers. The female workers are likely to make reports related to their safety. Therefore, the attitude of silence is risky behavior that can negatively impact the efforts to prevent injuries in the workplace. According to Adhikary, Keen, and Van Teijlingen, the employer is unable to mitigate the accidents in the workplace when they are not aware of the injuries or the accidents that the workers faced(2019). Therefore, the managers should always encourage the employees to be open and make injury reports. This can only be possible when they are educated on what is required and how their reports should be made.

Management Commitment

The management is supposed to be committed when it comes to enhancing the safety of its employees. They are a major component used in reducing injuries and accidents in the workplace. Therefore, they must show a positive commitment and support for the safety and health measures in the organization. The management is also supposed to enhance a good attitude towards safety by collaborating with the employees (Williams, Hamid &Misnan, 2018). The perceptions of the management and the employees determine the workplace safety measures understanding. All of them are supposed to play a significant role in enhancing safety. Therefore, the management must be engaged in the actions of their employees as they try to ensure that they achieve the goals (Williams, Hamid &Misnan, 2018). Proper management commitment coupled with employee education as well as having the employees participate in these activities makes it possible for the manufacturing industry to abide by the set standards.

The management also plays a critical role in the success of safety programs. This is because they have to come up with policies that must be met and those which the employees must abide by. Although OSHA provides some general guidelines, the organization must have some established measures that guide the employees on safety (Zaira&Hadikusumo, 2017). At the same time, it is the management that makes planning when it comes to the training schedules and the training requirements. Therefore, failure to maintain proper standards is an indication that the organization has not committed to safety. Therefore, if the management is committed to making the employees aware of the safety issues, then it will be possible to reduce unsafe working environments (Zaira&Hadikusumo, 2017). Management establishes a culture that influences the attitudes and behaviors as well as the norms within the organization. Table 1 shows the safety measures and their ranking as well as how they enhance workplace safety.

Table 1: Safety Measures and their Effectiveness

	Safe Score	Rank
Employee Training	4.50	3
Safe Work procedures	3.78	5
Consultation	4.44	4
Safety Reporting	4.70	1
Management Commitment	4.65	2

Injury Management in the Workplace

Injury management refers to the process whereby the employer as well as the medical team provides proper support to an injured employee until they can return to suitable employment. It is an important process because it helps to;

I. Provide physical as well as psychological and financial support

II. To minimize disruptions at the workplace

III. Reduce the costs

Safety in the manufacturing industry can be defined as a state where the probability of harm or damage to property is minimized to a certain acceptable level. Therefore, for safety to be enhanced, the risk of harm must be lower (Taufek, Zulkifle&Kadir, 2016). As such, injury management is a safety tool that must be kept in place to manage workplace injuries and accidents. However, they require that the right legislation or regulations are put in place.

Workplace Hazards Contributing to Risk of Injuries

Physical Exposure

Physical exposure refers to the workplace environment or the tools and machine operations that directly pose a risk of injury (Varghese et al., 2020). Some of the physical exposures at the workplace which increase the risk of injury include;

1. Manual handling of materials or finished products

2. Using highly repetitive motions in short cycles

3. Maintaining awkward postures especially at the neck and trunk

4. Working at a height

5. Operating a machine

Psychological Exposures

Psychological exposures are those that are associated with the changing work demands as a result of the economic and social requirements at work. The emerging technologies are exposing the employees to some form of psychological stress because there is a continuous need to keep coping with the ideologies and the global competition. According to Varghese et al., there is a direct relationship between stressors and the risk of the employees getting a work-related injury in the workplace (2020). Some of the stressors that can pose a risk include;

1. Increased work intensity

2. Monotony or doing the same job day-in-day-out

3. Pressures to meet the set deadlines

4. A huge mental workload

5. Isolation from the other employees

Work Organization

The world in the manufacturing industry has adopted the 24-hour economy. This means that there are shifts to make sure the employees work to enhance their competitiveness in the organization. The global competition when it comes to the production of goods has made it possible for all the companies to work towards success. According to Kowalski-McGraw et al., employees lack the traditional work schedules (2017). This means that they work irregularly when they are required to. Some have long working hours and in some instances, they are shorter.

Workers who take rotating shifts are likely to be more fatigued and they have a decline in performance and efficiency. As a result, there is a high risk of errors in their work. According to Lucas et al, the night shift employees are exposed to a high risk of injuries and accidents compared to day workers (2020). The same case happens when the employees are working overtime or for long hours. When they have shorter sleep as well as fatigue, their cognitive functioning slows down as well as their response time.

Individual Factors

In the workplace, individuals have different susceptibilities to workplace injury. According to Schulte et al., the younger workers and those with little educational background are more likely to have accidents as opposed to older and educated ones (2017). The same case applies to novice workers who are likely to forget the safety procedures and hence result in an accident or injury. Therefore, some of the individual factors that can result inan increased risk of accidents and injuries include;

Gender

Women are continuously participating in carrying out different activities in the manufacturing industry. According to Schulte et al., statistics show that women are at a higher risk of workplace injury compared to men (2017). This is because men are likely to receive more training on workplace injuries compared to men. However, the numbers suggest that more men are dying from work-related injuries compared to women. This can be attributed to a lower number of women in the workforce. Figure 3 shows the number of deaths by gender from 2003 to 2018 in the United States.

Figure 3: Occupational Deaths from2003 to 2018

Age

The distribution of jobs by age shows that young workers are more likely to work in risky jobs. Therefore, it means that they are more likely to be injured within the workplace. At the same time, the young workers are more likely to work in manufacturing companies that have not efficiently adopted the OSHA regulations (Vinodkumar&Neethu 2017). The young workers are less likely to receive safety training before commencing their work. As a result, they are left vulnerable due to poor protective measures or regulations.

Health

According to Baker and Palacios, health impairments can play an important role in preventing compliance with safety measures in the working environment (2020). They can also lead to a high risk of accidents and injuries. Health problems such as hearing impairment increase the risk of injuries. Other health issues such as psychological issues also can lead to stress and depression and result in an acute occupational injury.

Occupational Safety and Health Practices

Occupational safety and health practices are the policies and the activities as well as procedures that are implemented in an organization to enhance the safety of the employees. In the manufacturing sector, these practices are likely to reduce the chances of accidents happening. The accidents can be prevented by making employees aware of such risks so that they can take precautionary measures (Baker & Palacios, 2020). There are various components of Occupational Safety and Health Practices in the manufacturing sector.

Management Contribution

The management should be in the first position when it comes to the enhancement of safety. The management should consider the safety issues in the workplace during the time of the formation of the company. This is when they should determine the hazards available as well as the safety goals, programs, and the effectiveness of each of them (Kica&Rosenman, 2018). It is through early preparation that it becomes possible to manage all the vulnerabilities.

Training Employees on Safety

All the employees in a manufacturing plant come in to bring their skills and knowledge to enhance the performance. However, the company understands the safety issues that they may be faced with as they carry out their duties. This is determined during the audits which target to identify the safety gaps and the level of compliance in the organization. Therefore, when an employee is incorporated, one of the training topics must be in the safety in the workplace (Kica&Rosenman, 2018). These training programs are supposed to promote safety as well as prevent accidents and enhance compliance with the set standards. It should also incorporate the response measures that the employees should undertake in any situation.

Involvement of the Employees

The employees are the ones who are on the company floor every day. It is important, therefore, to involve them in understanding the safety challenges they face. They can identify the sources of the hazards and how well they can be mitigated (Kica&Rosenman, 2018). The employees must be encouraged to give feedback because it only through this that the safety-related issues can be identified.

Safety Procedures

These are the regulations that are put in place on how safety in the workplace should be enhanced. An example of a safety procedure is the definition of the time after which inspections must take place in an organization. The main aim of the safety standards is to set up standards in the way the employees should behave. However, the management is responsible for communicating these procedures to the employees.

Safety Promoting Policies

The organization should undertake some measures and activities that are meant to enhance the adherence to the safety policies that have been established. These can include providing recreational activities meant to motivate the employees to uphold safety standards (Dollard et al., 2017). At the same time, the organization may adopt the use of rewards to those who adhere to the policies. The employees can also receive incentives for upholding the standards.

Benefits of Occupational Safety and Health Practices

When an organization implements the required safety standards, several benefits come up.

Reduced Injuries and Fatalities

When the right safety measures are in place, the employees carry out their duties with precaution and as per the established work requirements (Dollard et al., 2017). This means that it minimizes the possibility of death or injuries.

Enhanced Business Image

The use of occupational safety and health practices makes it easier for stakeholders to assess the social responsibility of the organization. A good record of safety in the organization results in an improved image and brand value.

Enhancing Investor Confidence

Investors want to be associated with manufacturing companies that are known to adhere to the set of laws and regulations. Implementing occupational safety and health procedures helps to ensure that there are no issues when it comes to the safety of the employees (Dollard et al., 2017). The investors will be pleased to work with such manufacturers because they will have little to no fines for deviating from the OSHA standards.

Types of Hazards in the Manufacturing Industry

When workers are working in the company, they can be exposed to several hazards. Some of them include;

Noise

Loud noise from the machinery can be a source of hearing impairments to the employees. Loud noise is defined as the sound that makes one unable to be heard by another when speaking to another person (Nuruzzaman, Singh & Gaur, 2020). Most employees working without protective equipment can be adversely affected by noise.

Chemical Hazards

The manufacturing industry uses several types of chemicals such as cleaning products, hydraulic oil, disinfectants,and others. The employees working and using these chemicals are said to be handling hazardous chemicals (Nuruzzaman, Singh & Gaur, 2020). Therefore, exposure to them irrespective of the duration can lead to health problems. When they come into contact with the skin then they can cause problems.

Airborne Hazards

These are the hazards that include dust, gases, and vapors. Some of the sources of fumes in the manufacturing setup include spray painting as well as glue vapors(Nuruzzaman, Singh & Gaur, 2020). Therefore, when one is exposed to these fumes then they can result in some threatening illnesses such as lung impairment.

Exposure to the Sun

Sun exposure is common to the people who work outside under direct sunlight. It includes transport workers (Nuruzzaman, Singh & Gaur, 2020). High exposure to the sunlight can result in skin diseases and hence harmful to the employees.

Vibration

The equipment and tools used in the manufacturing process can cause vibrations. These include grinders, electric saws, and milling machines. The vibrations can cause numbness and reduce the ability of the employees to detect and feel vibrations, health, and cold (Nuruzzaman, Singh & Gaur, 2020). Table 2 shows the classification of injuries and the number of accidents and the losses they cause.

Table 2: Injuries and Deaths in the Manufacturing Industry

Types of Injury	Number of Accidents	Working-days lost	Wage loss
Death	21, 232	127,392,000	$573,234,000
Permanent total disability	1,728	10,388,000	46,656,000
Permanent partial disability	106,629	51,494,357	231,724,607
Temporary total disability	2,324,418	37,915,613	170,620,239
Total	2,453,418	227,109,970	1,022,264,866

Measures to enhance Safety in Manufacturing

Health Safety Programs

Health safety programs are meant to enhance the training of the employees about the use of the machinery and the PPEs. It also incorporates training them on emergency response to enhance their morale and productivity.

Personal Protective Equipment

The employees should be provided with PPE such as safety helmets and goggles. This ensures that they are less exposed to the contaminants (Murphy et al., 2018). It enables the workplace to be safe and enhances employee productivity.

Conclusion

In conclusion, workplace safety is the priority in the organization. The employees are supposed to be protected from hazards such as chemical as well as noise. The main aspect is that manufacturing companies should comply with the established OSHA standards. Some of the risks that the employees face include injuries and fatalities which can reduce their morale. Some of the causes of injuries include physical exposure where the employees are exposed to numerous risks within the organization. It can also be caused by individual factors. Some include health issues such as stress and lack of proper skills. Therefore, the manufacturing sector needs to work in enhancing safety and ensure the employees are protected.

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