Valuing your human 'cogs' and keeping them safe

We don't think of our plant employees as just another piece of manufacturing equipment. Perhaps it's time we should. After all, when things are running well, don't you go into the corner office and tell your CFO that the floor “is running like a well-oiled machine?” Don't you suggest in the staff meeting that productivity gains are due to your staff “working like cogs in a gia...


We don't think of our plant employees as just another piece of manufacturing equipment. Perhaps it's time we should.

After all, when things are running well, don't you go into the corner office and tell your CFO that the floor “is running like a well-oiled machine?” Don't you suggest in the staff meeting that productivity gains are due to your staff “working like cogs in a giant machine?”

Our employees are not machines, of course. Our employees send their kids to college and face the mortgage crisis and celebrate birthdays and experience moments of faith and joy and challenge %%MDASSML%% things that don't happen to your average stamping machine.

But your average stamping machine has a personalized program of scheduled maintenance. It gets regular attention to keep it running smoothly, it gets special attention when something breaks and it receives regular software upgrades to keep it current with the latest innovations. The result is a machine that runs efficiently and safely and, as a result, provides value for your organization.

Do you have the same program for your employees? Do you make sure they are trained? Do you provide them with the attention to sense when things are wrong and to offer them incentives when they succeed? Above all, do you make sure they are safe on and off the job?

Unsafe manufacturing is a pet peeve of mine. There's simply no excuse for an unsafe workplace. When workers are treated as commodities rather than those valued cogs %%MDASSML%% or worse, when you believe they can be replaced with the same ease as any cog %%MDASSML%% then you have a recipe for tragedy. A disaster is when things are broken. A tragedy is when people are broken. It's important to understand the difference.

Workplaces in the U.S. are generally safer today than ever before. From a global manufacturing perspective, we have a long way to go. China's factories and mines are unsafe at any speed, and they're hardly alone in the world.

We have yet to conquer the global issues of too-long work days, inadequate training and slipshod equipment maintenance. Until we do, the issue of wages will be offset by the challenges of workplace injuries and fatalities. When taken in that context, the total cost of manufacturing still favors the American worker. It's a message overlooked in many quarters, yet a number of Labor Day studies touted American workers as among the world's most productive. Norway was first and the U.S. was second. That's easily explained. Norway doesn't have fantasy football leagues.

If you want to make a case for American manufacturing, start with safety. That's a point we make in this month's cover story. If you are willing to make the same commitment to your people as you are to your equipment and to the finished product, the finished product will reflect that commitment to people.

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.
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.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

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

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