Analyst Insight: Years ago, America transitioned from a manufacturing economy to primarily a service economy. Recently, reacting to the supply chain issues of the pandemic, new tariffs and more, manufacturing in the U.S. has undergone a resurgence. Companies implementing advanced manufacturing technologies gain efficiencies, but those who also integrate advanced safety products and procedures will be best positioned for long-term success. 

Manufacturing companies have always strived to operate as efficiently as possible while maintaining quality and keeping people out of harm’s way. Today’s technologies include an increased use of robotics, computer numerical control (CNC) machinery, driverless forklifts and other autonomous machines. More equipment is automated than ever before, delivering high efficiency but also creating more workplace hazards. 

These advances have caused a workforce shift from manual labor to skilled technical workers. In addition, well-trained maintenance personnel are needed to keep the technologies operating at peak efficiency and mitigate downtime. Though the labor force will be smaller due to automation, it will be highly skilled and difficult to replace. Manufacturers must modernize their safety procedures accordingly. 

Following are several prevailing safety solutions that manufacturers can use, as new facilities are built or existing ones are updated.

Designated pedestrian lanes. Separate human and robotic work zones keep people away from dangerous, fast-moving equipment. Programming constraints help keep automated equipment out of the zones where people work. Railings and other safety markers and structures help keep people from accidentally drifting into hazardous areas. 

Multi-level factory designs. Placing machinery on lower levels with human oversight above provides a barrier that protects people and often also ensures the most efficient operation. 

Protective clothing and guarding systems. The tried and true still works. OSHA-approved personal protective equipment (PPE), guardrails, walkways with crossover platforms, fixed-access ladders and more help prevent workplace accidents and reduce downtime. 

Non-conductive materials. Electricity flows throughout manufacturing facilities, delivering power while reducing emissions. But people and electricity don’t mix. Plants with metal structures and components put people at risk of deadly shocks. Modern factories should include non-conductive materials such as fiberglass composites wherever possible. 

Corrosion-resistant materials. Robotics and other processing solutions can generate heat. Many manufacturing facilities utilize water or chemicals, or they may be in a climate with rain and snow. As a result, many plants experience high levels of humidity and moisture, which in turn cause metal structures to rust and weaken. Using corrosion-resistant building materials protects people from damaged walkways and rails as well as reducing the risk of substructures failing. 

Safe access. To keep maintenance crews safe without shutting down all — or even a segment — of the plant, access solutions must be built into every plant design. Fixed access ladders, stair towers, catwalks with proper guardrails and more can allow the crew to perform most routine maintenance from a safe position without disrupting manufacturing operations. All safety and access structures should be constructed with nonconductive, corrosion-resistant materials. 

Resource Link: https://oscosafety.com/

Outlook: These solutions exist today, so the future of American manufacturing — and manufacturing safety — looks bright in every aspect. The major factory investments being made now and over the next few years will ensure not only state-of-the-art manufacturing quality, but also superior protection of the valued staff. Companies that integrate safety planning into the designs of their facilities can reap the benefits of efficient domestic production, and retain a workforce that feels respected and appreciated.