Safety is good business

A sound safety strategy can save money and drive productivity increase, research finds.


Chris Brogli from Rockwell Automation spoke at Pack Expo 2014 about safety. Courtesy: Anisa Samarxhiu, CFE MediaEvery 15 seconds, someone dies from a workplace-related injury and 160 workers are injured on the job each day. The costs of such injuries are estimated at $1.25 trillion, which is about 4% of the world's Gross Domestic Product. A safer work environment, on the other hand, not only minimizes injury costs but also can increase productivity by 5%.

Chris Brogli of Rockwell Automation used that data from The Aberdeen Group in a presentation to an audience at the 2014 Pack Expo in Chicago. Brogli told the audience that manufacturers with the highest efficiency also had the lowest number of work-related injuries.

While both OEMs and end users focus on safety, they also have challengers when it comes to improving safety. The OEM is focused on driving throughput for the plant and providing flexible machines. The end user is focused on increasing the OEE of machines, reducing the time needed for repairs and changeovers, and productivity.

Brogli said a more collaborative effort that focuses on implementing safety at the design stage can help both OEMs and end users achieve a safer and more productive plant.

Among Brogli's suggestions for end users were to:

  • Add well-defined machine speculations
  • Have well-defined requirements, procedures, process to ensure compliance
  • Use standardized products and solutions to drive consistency
  • Have well-defined design and collaboration process with equipment suppliers
  • Have well-defined factory acceptance performance requirements
  • Have well-defined site acceptance. Even combining separate safe machines can create new safety problems.

Brogli said good safety specifications are important and should be detailed. Safety review checklists should be long and comprehensive so manufacturers don't worry about work-related injuries and the cost that comes with them.

Among Brogli's safety suggestions for OEMs:

  • Have a well-defined machinery design process that includes customer collaboration.  
  • Have modular, scalable, and integrated approaches.
  • Consider flexibility in the design process.
  • Utilize machinery assessments early in the design phase to identify machine risks. This way the problems can be detected early and fixed before ever even being put on the plant floor.
  • Use contemporary solutions that minimize components, wiring time, and maximize efficiency.

Contemporary solutions include safety embedded in all equipment as well as reducing the actual machinery on the plant floor. By having safety embedded in the drives, I/O, servos, and PLC, the end user can have all of their information displayed on one HMI screen.

- Anisa Samarxhiu, digital project manager, CFE Media,

No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Safer human-robot collaboration; 2017 Maintenance Survey; Digital Training; Converting your lighting system
IIoT grows up; Six ways to lower IIoT costs; Six mobile safety strategies; 2017 Salary Survey
2016 Top Plant; 2016 Best Practices on manufacturing progress, efficiency, safety
Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Big Data and bigger solutions; Tablet technologies; SCADA developments
SCADA at the junction, Managing risk through maintenance, Moving at the speed of data
What controller fits your application; Permanent magnet motors; Chemical manufacturer tames alarm management; Taking steps in a new direction
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Motion control advances and solutions can help with machine control, automated control on assembly lines, integration of robotics and automation, and machine safety.
This article collection contains several articles on creating and enhancing a safe workplace in manufacturing.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
click me