The potential for accidents and catastrophes in industries, especially for an industry 4.0 company, is immense to say the least. A lot of complex machinery and technology goes into it, which explains all the risk. 

It is for this very reason that robust safety measures should be in place to protect industry workers and the machinery alike. This article covers all the basics of industrial safety.

Let’s get right to it:

What Is Industrial Safety?

Industrial safety envelopes lots of things, from general safety to environmental safety. In essence, industrial safety refers to the set of safety protocols put in place to protect workers, equipment, the workplace, and the environment from hazards. An industrial safety company should have multifaceted safety policies and strategies simply because the risks come in many shapes and forms.

The Main Types of Industrial Safety Hazards

As I had mentioned, safety hazards come in all shapes and forms. They are mostly classified by how they threaten operations and the party or parties involved.  The particulars include:

Physical Hazards

These occur when the risk posed is to those standing in or around the workplace in question. Top instigators in this category include noise, radiation, and temperature extremities. Where to begin?

I don’t have to explain the kind of complications that noise pollution brings. It starts with perhaps some mild tinnitus and ends with possible permanent hearing loss. Long term exposure to noise pollution is the recipe for long term hearing loss. 

The worst thing about noise pollution is even harmless sounds like a vacuum cleaner can cause ear damage if exposed to it long enough. On top of the hearing damages, noise pollution also causes lots of stress as well as reduced productivity from the constant distractions.

Radiation is in line with industries in the radioactive material business like in nuclear power stations. Exposure to radioactive substances always demands immediate critical emergency management. Workers under such risks should be prepared for such unfortunate events.

Last on the hot seat, excuse the pun, is temperature extremities. Extreme temperatures on both ends of the spectrum can really mess up one’s thermoregulation. Heat stress for one occurs from high temperatures from furnaces or any heat-emanating device. 

Heat stress can result in rash, heat stroke, and muscle cramps. On the not so hot side, the biggest risk is hypothermia when working in freezers or coolers. Other risks in cold temperatures include frostbite.

Chemical Hazards

Chemical hazards certainly need no introduction. Any chemical you see at work with a skull sign basically falls under this category. 

Chemical hazards arise from hazardous chemicals that can cause harm, from inhalation or simply touch. Handling this as an industrial safety company means training all your staff on safe work operation practices. 

On top of that, equip them with personal protective equipment as the last line of defense for some level of protection in an accident.

Biological Hazards

Biological hazards are indeed from tiny living organisms that cause illnesses like viruses or bacteria. Although something like a flu may not require as complex critical emergency management as a uranium mishap, it still shouldn’t be undermined. 

This is because the illness may be contagious and it ends up spreading through your entire workforce and you are left counting losses with the drop in productivity. Imagine half your staff calling in sick for work.

Safety Hazards

Safety hazards are perhaps the textbook definition of occupational hazards. Work in electricity? It is plausible you will be shocked at some point in your career. 

Other examples of safety hazards include falls from working at heights or cuts from using sharp machinery. These risks may not be as profound in an industry 4.0 company because of all the automation but they are hazards nonetheless. 

The main idea behind connected workers as a technology is providing you as a manufacturer real-time visibility into all your processes by digitizing and augmenting operator workflow. 

Digitizing the workflow helps in improving the effectiveness of your workforce and how is this achieved? 

It is achieved by linking all your workers with access to information to make better decisions. In any industry, especially industry 4.0, frontline workers need timely access to information to effectively do their jobs. This timely access to information is what a connected worker solution provides.

Choosing a Solution

These solutions are all digital software tools that are combined with mobile and wearable devices to improve communication, collaboration, guidance and support in complex industrial scenarios like manufacturing. 

Now you are faced with the conundrum of choosing the perfect solution for your company. Ask yourself these questions to help you make your decision:

Who Are You Connecting?

The whole idea is connecting workers ergo the term connecter worker so who exactly do you need to connect? The answer to this question will help you pick which path suits your needs best. 

You could connect field workers in remote sites or operators on high-mix assemblies. Beyond answering this question, you need to figure out exactly what you need from the solution. Do you only want to connect them or augment some management features as well? 

Basically, identifying who you are connecting will establish a foundation of exactly what you need from a solution so it’s easier to pick a solution in the review process.

What Are They Doing?

In this step, consider what your workers are doing and how connectivity will help them do their jobs considerably better.

What Systems Do Workers Interact With?

Answering this question will help you see which workers are part of which connected system and how they are part of it. Consider just how connected to the system the workers need to be. 

Answer some secondary questions like which software will they interact with, what IoT devices are involved and which machines are involved. 

Another important question you shouldn’t overlook in this step is what will the solution add to these systems that doesn’t already exist? You may need to incorporate some asset management solutions in this step to monitor information on all systems.

How Do the Connected Workers Actions Affect the Work That Gets Done?

This question all boils down to worker contributions in the manufacturing process. In a way it doubles up on the first question. These solutions act as asset management solutions in the monitoring of the result of human/worker action in the manufacturing lines.

To optimize this step, identify those contributions from your personnel that technology cannot do and pick a solution that optimizes human performance with regard to said contributions.

Proneness to Error

They say man is to error and as true as that is, it’s not always a result of human poor performance. Sometimes, poor system design contributes to human error. 

That said, ask yourself exactly where in the production line the workers are making errors and what kind of errors they are. While at it, identify the root cause of these errors as well.

What Data Will Make a Difference for You?

The main reason for connected worker technologies goes way beyond just making humans more efficient. The part of data collection about human action is often overlooked.

You want the solution you settle on to have a difference in your operations – a significant difference at that. Consider 4 things:

What do you want to know? What do you already know? What data is difficult to collect with the current technology? And how much paper are you using?

You know what they say about information being power and well, data is just information. These solutions are crucial tools for collecting data that matters.

Companies may increase employee safety by using a process safety management system when there are extremely toxic, flammable, explosive, or reactive chemicals present. This is crucial in operations that involve handling, utilizing, storing, transporting, and generating very hazardous chemicals that offer significant safety and health risks to the project’s workforce.

As an analytical technique to monitor how these compounds interact with one another, process safety management was developed. Accidental chemical releases can occur at any time, but many firms are able to keep their staff safe by looking for measures to lessen the risk of unforeseen spills or leaks involving such substances.

Components of the Safety Process Management System

Process Safety Information

All information about dangerous chemicals must be compiled by the employer into a record for future use. Prior to doing any process hazard analysis, this must be completed. 

Information about the technique and equipment used in the operation, as well as the substances used, must all be included in the report.

Process Hazard Analysis

The goal of this study, which must be carried out every five years, is to prioritize the biggest risks and address the most pressing ones first. The study must be carried out by a group of engineering and maintenance experts as well as at least one experienced worker with expertise in that method. 

They will next make an effort to identify, evaluate, and finally control the danger that is there.

Training

The employer provides operator training that emphasizes the specific health and safety risks associated with the operation, good work habits, and emergency procedures. 

Refresher training is to be provided at the very least every three years. When the training is over, it is important to keep track of the date and a way to make sure the employees comprehended the safety instruction.

Change Management

It is necessary to manage changes in a facility psm, technology, equipment, and other pertinent operations using a sound methodology. 

The employer must take into account the technical justification for the change, its effect on worker safety and health, the operational modifications needed, the time frame for the changes, and the authorizations needed for them to happen.

Event Inquiry

An inquiry must be carried out within 48 hours following an event or close call involving the release of very dangerous chemicals. 

The report must include the incident’s date, a brief description, any contributing factors, and any recommendations that followed. These reports must be kept on file for at least five years following the occurrence.

Benefits of HOP Software

Human and organizational performance software provides you with cloud-based management software that combines all the features and tools required to manage your business with ease and generate significant revenue, regardless of whether you are in charge of a luxury hotel frequented by royalty and celebrities or a collection of cozy, rustic cabins tucked away in a forested paradise.

HOP software eliminates the requirement for purchasing or subscribing to several software or business systems by integrating all the tools you require into a single, unified platform. You do not need to have additional tools for controlling your income and separate software to manage reservations and bookings.

Running your business with a variety of various systems is difficult since it is time-consuming, laborious, and clumsy among other reasons. Additionally, it can have a highly negative impact on the efficiency of your organization, reducing your profit margins. 

Conclusion

In a facility psm program, visual communication is critical to eliminate misinterpretation and foster total mutual understanding. 

There is no assurance that staff will remember or be experienced enough to avoid emergency situations if no labeling or signs are posted throughout the site.