What are the most essential safety skills and competencies for the manufacturing industry?

Along with Hazard Identification, we should also study the Leading and Lagging Indicators because safety performance analysis would give us an idea about the weaknesses in the Safety Management System.

Modern safety training in manufacturing is no longer just about hazard identification; it’s a tech-enabled, proactive approach. Real-time sensors monitor conditions, sending alerts for potential hazards. Machine learning can predict issues, allowing preemptive action. VR and AR offer risk-free, hands-on training for hazardous scenarios. Cloud-based mobile apps put critical safety info at workers’ fingertips. Additionally, mental well-being is addressed through stress management training and wearables that monitor stress levels. Technology is driving a comprehensive, data-led safety culture, making the manufacturing workplace safer and more efficient.

Habilidade em identificar, avaliar e gerenciar riscos associados às operações de manufatura, incluindo análise de riscos de processos e instalações. Habilidade em desenvolver e gerenciar programas de saúde ocupacional, incluindo monitoramento da exposição a substâncias perigosas. Conhecimento em implementar e manter sistemas de gestão de segurança, como o ISO 45001, para garantir a melhoria contínua.

A primeira e mais importante competência é o entendimento aprofundado das normas regulamentadoras (NRs) aplicáveis, como a NR-12 (Segurança no Trabalho em Máquinas e Equipamentos), que visa prevenir acidentes operacionais. Outra habilidade importante é a capacidade de identificar e avaliar riscos, permitindo a implementação de medidas preventivas e corretivas para minimizar a exposição dos trabalhadores a perigos. A gestão de EPIs e EPCs também é fundamental, garantindo que os equipamentos estejam em conformidade e sejam utilizados corretamente.

Compreensão profunda das normas de segurança industrial relevantes para a manufatura. Conhecimento das regulamentações locais e internacionais que afetam a segurança na indústria. Ao desenvolver habilidades e competências, os profissionais da indústria de manufatura podem contribuir significativamente para a criação de um ambiente de trabalho mais seguro e protegido para todos os envolvidos.

Understanding and following your companies procedures and protocols is good, but you can do better! When reviewing procures and performing tasks, never be afraid to ask questions and bring forward potential improvements to both the task itself and/or the procedure documents. These documents are NOT infallible, nor are they always written in a way that everyone can understand them. Go out looking for opportunities to ask questions, make suggestions, and take part in their development. Some of the best procedures I have seen developed or amended, were thanks to field level involvement and feedback.

Ownership is key! As James L. notes in his comment, getting involved in the development of safety procedures and protocols by colleagues on the front line will make the procedures not only as close to how the task is actually carried out, but also an engagement tool for front line ownership. I look at many of the roles out there in health and safety and I believe that the function of many of these roles is not to always do, but to allow everyone to become a little bit better at what we know a lot about. Would you want me writing a safety procedure for any task in manufacturing? I very much hope not as I don't have that background. However, I can help guide from a health and safety perspective to improve. That's me adding value!

You may have the top class procedures & rules and still fail. Implementation, training and actions plays the key role here. Set clear expectations for employees, so clear that even top management understands what to expect :)

Complacency and poor supervision are the devil's advocates here. Companies have protocols is in place for a reason. Enforcing & following company procedures results in fewer injuries, a good reputation for safety, and more future work.

Compliance with safety protocols in manufacturing is vital but often seen as complex. Usability mapping can streamline this process, transforming dense guidelines into intuitive, role-specific procedures. This modern tool not only simplifies understanding but also enhances real-time communication among team members. The aim is to create a dynamic, easily navigable safety landscape where procedures are tailored to roles, equipment, and materials. Inter-departmental coordination is elevated, ensuring everyone is aligned with safety standards, making the workplace not just compliant but inherently safer.

Drill! Drill! Drill! In my experience, there is nothing like prepare for the worst whilst hoping for the best. As a simple example, one skill I learned when undertaking a train the trainer course was, during the housekeeping session, stand everyone up and make them walk with you to the nearest emergency exit. Why? Muscle memory. We all know that people learn differently so build this in - for those who learn by listening - tell them how to get there; for those who likes pictures - show them the emergency diagram; and for those who like doing - walk them to the exit! Don't rely on people knowing what to do, ask them to demonstrate it too. At my training sessions now, this is something I frequently undertake where appropriate.

Emergency preparedness and response are essential safety skills. Employees must be capable of operating emergency equipment, understanding evacuation procedures, and adhering to emergency action plans. Effective communication skills, including the ability to report and convey information during an emergency, are required. Basic first-aid knowledge and the ability to manage stress in high-pressure situations increase safety even further. Regular drills and training sessions assist employees in developing these skills.

Keep it simple clear and highly visual and drill the plans everyone at least once a year should be tested to show they understand what they need to do, audit the routes to ensure clear and well lite and maintain the equipment ensure checks are done regularly and that all statutory inspections are done by an approved contractor.

Na minha experiência, durante um incidente real, quando um pequeno incêndio eclodiu devido a um curto-circuito em um equipamento, os funcionários agiram rapidamente e de acordo com o plano. Eles usaram extintores de incêndio para controlar as chamas, acionaram o alarme de incêndio e iniciaram o procedimento de evacuação. A rápida resposta evitou danos maiores e demonstrou a eficácia do treinamento e da preparação para emergências. Esse caso destaca a importância de não apenas ter um plano de emergência, mas também garantir que todos os funcionários estejam familiarizados e confortáveis com os procedimentos, capazes de responder calmamente e eficientemente em situações de crise.

Despite preventive measures, emergencies like fires, explosions, spills, or medical incidents can still occur in manufacturing. Being prepared is key. Training ensures effective and safe responses to such situations. Familiarity with emergency equipment like fire extinguishers and first aid kits is vital. Understanding evacuation procedures, reporting protocols, and following the emergency action plan are essential. By being equipped and trained to respond promptly and appropriately, workers can mitigate risks and ensure safety during emergencies in the manufacturing industry.

Over-reliance on Personal Protective Equipment (PPE) by employers can be a red flag, signaling a reactive rather than proactive approach to safety. PPE is often the least reliable control, serving as a last line of defense rather than a solution. Modern safety practices advocate for better work design—structuring tasks, processes, and the work environment to inherently minimize risks. Through effective work design, hazards can be engineered out, making safety an integral part of the job rather than an added layer. This shift moves the focus from temporary fixes to long-term safety solutions.

It is the employer’s responsibility to pay for the employee’s PPE. The employer will also be responsible if the employee does not wear the PPE required.

Em todas as empresas para as quais desenvolvemos o Código de Ética e Conduta, os diretores solicitaram enfatizar a importância do uso adequado dos equipamentos. É crucial a utilização correta desses dispositivos.

This line sums up this section well "You also need to be aware of the limitations and risks of using PPE, such as false sense of security..." Remember - PPE does not stop incidents nor does PPE reduce the job hazards, but rather reduces the harm done should all other controls (elimination/substitution, engineering and administrative) fail. Don't believe for a minute that PPE is a paramount control measure - if you are relying heavily on PPE, you have failed to take meaningful action that would have otherwise had a higher potential to prevent an incident and potential injury from occurring.

A seleção e uso adequado de Equipamentos de Proteção Individual (EPIs) são vitais para garantir a segurança dos trabalhadores. Escolha EPIs específicos para os riscos presentes na tarefa. Considere fatores como tipo de risco,Eduque os trabalhadores sobre as limitações e riscos associados ao uso de EPIs,Realize avaliações periódicas para garantir que os EPIs continuem sendo adequados para as tarefas em evolução e as condições de trabalho,Mantenha-se atualizado sobre os requisitos legais e regulatórios relacionados ao uso de EPIs,Ao integrar essas práticas, você promove uma cultura de segurança eficaz, garantindo que os EPIs sejam uma parte valiosa e confiável do programa geral de segurança no ambiente de trabalho.

Information is power! People make decisions based on the information they have or how they interpret information they are given. If you provide the opportunities for learning and development, people tend to want for more and that can, in my view, only be a good thing! We can all learn something from each other and it is that combined information that truly holds the power to create sustainable improvements but we need to listen and value everyone's contribution.

One thing I’ve found helpful is to have a continued emphasis on safety awareness. This can be done by a weekly toolbox talk, or a monthly safety committee meeting.

Realize avaliações periódicas para garantir que os EPIs continuem sendo adequados para as tarefas em evolução e as condições de trabalho assim poderá aprender e melhora suas habilidades e competências com treinamento contínuos para criar uma cultura.

Whether the safety program is brand new or well established at your organization, adding regular safety meetings is always a good idea. We've found that when it comes to workplace safety, there is no better time to promote new ideas or reinforce safe working habits than in a safety meeting. Leading, participating, and engaging in short meetings that are specifically targeted to topics relevant to the team can prove to be an excellent way to contribute to a positive safety culture at your facility.

Un point essentiel également à mes yeux dans l'analyse des causes d'un incident/ accident/ presqu'accidents est de ne jamais arriver à une simple conclusion de "non-respect de la procédure". Ça n'est jamais une fin en soi: il est essentiel de comprendre pourquoi une procédure n'a pas été suivie si c'est le cas. S'agit-il d'un simple manque de formation/ assimilation? L'organisation réelle du travail permet-elle réellement de l'appliquer ou faut-il repenser la façon de travailler voire le processus? Etc.

The most important skill is continuous improvement. For this purpose, you should follow the conferences, discuss with your colleagues working in the same profession, and read plenty of reference books.

Even if you do everything you can to stop and manage dangers, unexpected events can still happen in the manufacturing industry. These could be things like fires, explosions, spills, leaks, power failures, equipment malfunctions, or medical crises. It's important to be ready and trained to handle these situations in a safe and effective way. You should know how to use the emergency equipment, like fire extinguishers, first aid kits, or alarms, that are available at your workplace. You also need to know how to evacuate, report, or help in an emergency, and follow the emergency action plan that is in place.

In my experience, fostering a safety mindset that transcends mere compliance is crucial. It’s about instilling a deep-seated understanding of why safety matters, empowering individuals to take ownership of their well-being and that of their colleagues. By promoting a culture of continuous learning, where feedback is valued and innovation is encouraged, we can adapt and thrive in the dynamic landscape of the manufacturing industry. Together, we can build a safer, more resilient workplace where every voice is heard and every action counts.

El conocimiento de normativas y regulaciones en materia de seguridad laboral es crucial para poder guiar, asesorar y motivar en los trabajadores, supervisores y demás funcionarios el cumplimientos de los elementos aplicables en su región y sector, como por ejemplo: OSHA en Estados Unidos, NOM en México, etc.