Understanding the Landscape Understanding PPE in Manufacturing

Personal Protective Equipment in manufacturing encompasses specialized clothing and devices designed to protect workers from job-related injuries or illnesses. This equipment includes items such as helmets, gloves, eye protection, and safety footwear—each serving as a critical barrier against workplace hazards.

The Indispensable Role of PPE in Manufacturing

The manufacturing environment, known for its inherent risks, necessitates robust safety protocols with PPE at their core. Here’s why PPE is essential:

Comprehensive Protection: PPE shields workers from a variety of dangers, including physical injuries from machinery and harmful exposures to chemicals and noise.

Regulatory Adherence: Compliance with is not just about following laws—it’s about actively protecting the workforce.

Injury Prevention: Effective PPE usage significantly reduces the likelihood of workplace injuries, which companies substantial amounts in healthcare and lost workdays.

Enhanced Morale and Productivity: A safe worker is a happy and productive worker. Knowing that their safety is prioritized can boost employee morale and output.

PPE for Manufacturing Safety

Hard Hats: In manufacturing environments where there’s a risk of falling objects, are crucial for protecting your head from impacts and preventing serious injuries.

Safety Glasses: To safeguard your eyes from flying debris or hazardous chemicals, wearing is essential.

Face Shields: For enhanced protection of your face, eyes, and mouth, face shields are often used alongside safety glasses or goggles in particularly hazardous manufacturing settings.

Earplugs or Earmuffs: Manufacturing facilities can be extremely loud, making it vital to protect your hearing with to minimize noise exposure.

Protective Clothing: Depending on the nature of your work, many manufacturing facilities mandate the wearing of protective clothing such as gloves, aprons, overalls, and boots.

Breathing Masks: To prevent the inhalation of toxic chemicals, you may need anything from a simple paper mask to a more sophisticated . Regular use of masks can also help avert long-term respiratory issues.

Successful Implementation

Implementing a successful PPE program involves several key steps:

PERFORM regular Maintenance and Inspection: Continuous upkeep is necessary to ensure the protective gear remains effective.

CONDUCT thorough : Identifying potential risks is crucial in determining the necessary PPE.

ENSURE PPE must be appropriate for the hazard and correctly fitted to the individual.

PROVIDE comprehensive Training: Workers should be educated on proper PPE use, maintenance, and its limitations.

Looking Ahead

In observance of Manufacturing Day, we’re reminded of the critical role safety plays in the industry. It’s the ideal time to reevaluate your safety protocols and enhance PPE practices, ensuring that every worker benefits from the highest standards of protection. Don’t compromise on safety!

For tailored advice on PPE optimization and consultations with experienced risk management professionals, visit /services/risk-management/

The information provided in this article is for general informational purposes only and does not constitute legal advice.  We recommend consulting with an employment attorney to ensure compliance with all applicable laws and to receive legal advice tailored to your specific circumstances.

Be sure to check out the risk management technology 91şÚÁĎÍř has to offer policyholder businesses at our new Risk Management Technology webpage!

Understanding the Problem Before Seeking Tech Solutions

Before diving into the realm of innovative technology, companies must first thoroughly understand the specific problem they are aiming to solve. Engaging with a novel tech solution showcased at a conference, without a clear and present need, can lead to inefficient use of both time and financial resources. This foundational understanding ensures that investments in technology are both strategic and beneficial.

Integrating Safety Technology

In the domain of workplace safety, technology should be considered only after applying the Hierarchy of Controls. This approach assesses whether a hazard can be outright eliminated or significantly mitigated through engineering changes rather than through behavioral adjustments alone. For instance, it is more effective and sustainable to automate a process or redesign a workstation to prevent strenuous physical tasks such as bending to lift heavy materials repeatedly, rather than to rely on wearable sensors that prompt workers to adjust their movements.

Overestimation of Product Adoption

Vendors often have a clear understanding of their safety technology’s capabilities; however, they may overestimate how eagerly such technology will be adopted by the workforce. Resistance to change is a common human behavior, particularly with interventions such as safety initiatives that require new habits or routines. It is crucial for management to recognize the extensive planning, management, and effort required to implement these technologies effectively. Underestimating these factors can compromise the return on investment and may even foster a perception among employees that the company is indifferent to their safety, potentially eroding the organization’s safety culture.

The Foundation of Safety Programs Before Tech Integration

Technology should not be seen as a panacea for all safety program deficiencies. A well-established safety program is a prerequisite before considering the integration of innovative safety tech solutions. Technology amplifies the effectiveness of what is already in place; it does not typically resolve the fundamental weaknesses of a safety program. For example, a robust safety program that utilizes safety management software effectively will enhance efficiencies and provide timely, actionable insights. On the other hand, a weak safety program may lead to the underutilization of such technology, wasting resources and potentially obscuring critical issues like poor hazard understanding.

Commitment to Safety Tech

For a successful integration of new safety technology, an organization must be willing to allocate sufficient resources, including time for a dedicated program champion or manager. The experience with telematics in the automotive industry illustrates this well; these devices have the potential to significantly improve driver behavior and reduce incidents, but only if they are actively managed. Passive installation without active monitoring, feedback, and accountability will not yield the desired improvements. Managers tasked with these responsibilities must have the capacity to handle them, underscoring the need for a thoughtful approach to capacity planning, incentives, and accountability mechanisms.

Key Takeaways

Problem Identification: Ensure that the specific safety issues are well-understood before integrating technology.

Hierarchy of Controls: Apply fundamental safety measures before considering technological solutions.

Realistic Adoption Expectations: Prepare for potential resistance and ensure robust management support for new safety technologies.

Safety Program Foundation: Technology should build upon, not attempt to replace, the foundations of an already established safety program.

Resource Allocation: Dedicate necessary resources, including personnel, to manage and monitor safety technology effectively.

Looking Ahead

Successfully integrating safety technology into workplace practices requires more than just acquiring tools. It involves a deep understanding of specific problems, strategic application of safety measures, and a solid foundation in existing safety programs. The commitment of the entire organization, from management to every team member, is crucial for leveraging these technologies to enhance safety outcomes and promote a culture of continuous improvement and innovation.

As part of its involvement with the National Safety Council’s (NSC) to help prevent these types of injuries, 91şÚÁĎÍř’s Risk Management team has been awarded a safety grant through the NSC’s MSD Solutions Lab. Participation in the “Pilot Grant 1.0” program will include the selection of two policyholders who will leverage analytic video assessments and exoskeleton wearable devices through exclusive technology partnerships with 91şÚÁĎÍř. These companies will be recognized for their involvement and the results can aid in advancements to reduce worker injury rates and absenteeism.

“As pioneers in workplace safety solutions, we always prefer to help prevent an employee’s injury altogether. This is why we are very excited to assist the NSC’s MSD Solutions Lab with their work to develop repeatable solutions that improve workplace safety,” said Ryan Anderson, risk management expertise specialist at 91şÚÁĎÍř. “The program provides us an opportunity to pilot safety technologies and determine the impact these solutions can make on musculoskeletal disorders.”

Following an application and screening process, 91şÚÁĎÍř will select policyholders for the program this fall. Participating policyholders must be exposed to the types of ergonomic safety risks related to the pilot technology; already be proven champions for safety at their organization, with a strong safety culture; and be willing to share the resulting data from the pilot program for a future case study.

“We are thrilled to be identified among the nation’s top safety innovators and work together with the NSC in implementing cutting-edge solutions for the prevention of workplace injuries,” said Kevin Clary, 91şÚÁĎÍř’s vice president of risk management and premium audit. “Our company’s participation in the grant program speaks to our service differentiator of identifying and offering emerging safety technologies to the benefit of our agency customers and policyholders.”

91şÚÁĎÍř is a founding member of the National Safety Council’s safety advisory group to help prevent workplace injuries. Funded by Amazon and implemented in 2021, the council seeks to address risks associated with musculoskeletal injuries and drive initiatives to prevent workplace losses by engaging key leaders and stakeholders, leveraging technologies and implementing prevention solutions.

As part of the council participation, 91şÚÁĎÍř was also recently awarded the MSD Solutions Index Badge, which represents the company’s commitment to reduce the most common workplace injuries.

To learn more about the NSC and the safety grant pilot program, .

Work-related musculoskeletal disorders (MSDs) are a leading cause of occupational injuries and illnesses in the U.S. These disorders develop when workers are exposed to biomechanical forces that regularly exceed the worker’s physical capabilities, such as lifting, extreme postures and extended efforts. Overhead work is recognized as a leading cause of work-related musculoskeletal disorders to the shoulder, arm and neck.

Passive Exoskeletons to Prevent MSDs

An exoskeleton is a wearable device that provides physical assistance to the wearer through structural support and assistive torques. The devices are worn on the worker’s body and follows their movements. Because of the tight fit and following of the wearer’s body movements, job functions rarely need to be altered to accommodate the exoskeleton.

Passive exoskeletons are one device type that requires no energy source and are lighter and less bulky than powered exoskeletons. Passive exoskeletons take advantage of mechanical activation, springs and dampers to store energy and transfer force to the heavier muscles of the body. These actions can significantly remove physical strains on the arms, shoulders and neck while performing overhead work.

91şÚÁĎÍř Pilot Program

91şÚÁĎÍř is beginning a pilot program to evaluate the use and benefits of exoskeletons in the workplace. As part of the pilot, 91şÚÁĎÍř has partnered with Ottobock to provide shoulder exoskeletons to support policyholders performing overhead work. The exoskeleton provides shoulder and arm support and fits workers from 5’2 to 6’2 with adjustable support for the overhead work.

“The exoskeleton pilot will enable the company to obtain feedback from policyholders on the acceptability by workers, benefits of use and, ultimately, lead to improved worker safety for more policyholders,” said Dave Galbraith, 91şÚÁĎÍř’s AVP Risk Management and Technical Lead.

For more information or to participate in our pilot programs, contact your risk management consultant.

, an annual event organized by the Occupational Safety and Health Administration (OSHA), strives to help reduce the rate of worker deaths and injuries through effective organizational safety planning and education and connects organizations with resources to keep their workforce safe.

Health and safety programs should play a vital part in any business, especially for roles in industries where workers may be at a higher risk of injury or illness. Businesses in construction, manufacturing and healthcare should consider becoming involved in Safe + Sound Week to improve safety for their teams. Below are just a few ways to participate:

• Enhance Your Programs: including toolkits, courses and recommended best practices for implementing health and safety programs for your business.
• Join a Safety Event: Identify virtual and in-person activities and events your team can participate in to further promote workplace safety by accessing the Safe + Sound week national .
• Share Your Participation: Participate in this year’s events (or proactively plan activities for next year) and receive a certificate of recognition from OSHA for your organization’s efforts.

Safe + Sound Week provides a great opportunity to maintain and improve your safety programs. Implementing strong practices can keep workers safe and healthy which supports your bottom line.

91şÚÁĎÍř’s Risk Management experts continuously pursue the latest in safety technology with an emphasis on preventing losses through safe work practices. In-person and digital occupational safety and health training programs and resources, such as connected wearables, virtual reality training, and organizational safety surveys, can help reduce and prevent injuries and illnesses at work by identifying and addressing potential hazards on the jobsite. Learn more about 91şÚÁĎÍř RM by clicking here.

Originally patented as the “Hard-Boiled Hat,” the protective headwear was made of steamed canvas, glue and black paint. The first official construction jobsite that required hard hats was the building of the Hoover Dam in 1931.

Since then, the hard hat has evolved tremendously.

Material matters
Hard hats were first made of steel, then aluminum, fiberglass, thermoplastics and high-density polyethylene. Over the years, various additions have been made, such as face shields, light visors, earmuffs, mirrors, electric lamps, radios, cameras and more.

Safe from struck-by hazards
Regardless of the material, hard hats have always been designed as a way to protect against struck-by hazards. Struck-by hazards are considered one of the Occupational Safety and Health Administration (OSHA) Fatal Four Hazards.

Hard hats are only effective at preventing struck-by injuries when they are worn at all times if overhead work is being completed by any contractors on site. They should be inspected for cracks, gouges, dents or other damage before each use. Damaged or worn out hard hats should be replaced immediately.

Remember, hard hats, like all other personal protective equipment, are the last line of defense on a jobsite. Preventative worker safety measures should always be used to proactively avoid injuries and loss.

What’s next?
Just like hard hats were revolutionary in 1919, wearables are a proactive way to protect workers today.
Some hard hats are now being fitted with wearable technology which can monitor heart rate, body temperature, and whether or not the wearer is actively moving.  91şÚÁĎÍř’s current wearables pilot program tests wearable technology as a means to prevent injury from lifting, bending or twisting. The goal is the same — to reduce Workers’ Compensation claims, injuries and loss.

In the next 100 years, there are sure to be many more advances in personal protective equipment and other jobsite safety measures. What will remain the same, however, is the need for proactive safety measures. Jobsites that embrace a proactive safety culture will experience fewer business interruptions and protect their bottom line.