2016 Safety Study: Seven key findings

Respondents to the Plant Engineering 2016 Safety Study identified seven high-level findings impacting the manufacturing industries,

10/03/2016


Source: Plant EngineeringRespondents to the Plant Engineering 2016 Safety Study identified seven high-level findings impacting the manufacturing industries today:

  1. Commitment to safety: More than two-thirds of senior management and operations personnel are very committed to safety in their facilities, followed by line supervisors (55%) and line workers (48%).

  2. Work group safety: The work groups that feel the safest in their daily tasks are plant management/corporate executives (74%), safety executives/managers (70%), and engineering (61%).

  3. Safety programs: Ninety-seven percent of respondents believe their employees feel safe on the job, and 83% have observed an increase in productivity over time due to the implementation of a safety program. The costs of injuries and insurance claims have also decreased since following a safety program.

  4. Enforcement: More than 70% of facilities hold regular safety meetings, perform safety audits, and have established a safety committee in order to enforce safety methods. Another 69% have implemented job safety analysis procedures.

  5. Safety meetings: The majority of safety meetings are held on a monthly basis, and the most active contributors are safety executives/managers (67%), plant management/corporate executives (66%), line workers (63%), operations (61%), and maintenance personnel (60%).

  6. Safety strategies, technologies: The top strategies or technologies that facilities use to enforce safety include personal protective equipment (86%), lockout/tagout procedures (78%), job safety analysis (69%), and internal safety audits (68%).

  7. Measuring success: Three-quarters of facilities measure their safety success by their number of accident reports and near-miss events, while 68% compare their OSHA recordables/time-lost accidents, and 43% observe lower workers’ compensation costs. The average facility has experienced two OSHA-recordable incidents within the past 6 months, only one of which resulted in lost time.

Access the full 2016 Safety report to view additional key findings.



Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2017 Top Plant.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
March 2018
SCCR, 2018 Maintenance study, and VFDs in a washdown environment.
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
February 2018
Focus on power systems, process safety, electrical and power systems, edge computing in the oil & gas industry
December 2017
Product of the Year winners, Pattern recognition, Engineering analytics, Revitalize older pump installations
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
April 2018
Implementing a DCS, stepper motors, intelligent motion control, remote monitoring of irrigation systems
February 2018
Setting internal automation standards

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

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
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 Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Maintenance & Safety
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Industrial Analytics
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
IIoT: Operations & IT
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me