Identifying and preventing common workplace hazards

When you oversee a manufacturing operation, safety is always one of your highest priorities. Even so, injuries will occur from time to time, but you can minimize the risk for workplace accidents by taking some precautions.

Common hazards

The Occupational Safety and Health Administration reports that in 2011 – the most recent year for which data is available – 40 percent of manufacturing accidents were caused by “contact with objects.” Included in that category are injuries caused by contact with or entrapment in equipment, being struck by an object or equipment, or striking against an object or equipment. Reducing the risk of contact injuries begins with a careful inspection of your shop area.

Safe stacking

Safe storage is extremely important in warehouse and manufacturing operations. To conserve space, items may be stacked on top of each other, but employees need to understand and follow guidelines on how to stack items. Following are some of OSHA’s specifications for stacking items:

Lumber may be stacked no more than 16 feet high, if workers will be handling it manually, or 20 feet high, if a forklift is used to stack lumber

When stacking drums or barrels, a secure flat surface – such as plywood dunnage – should be placed between each row of items, and when stacking more than two rows high, the bottom layer must be immobilized with chock blocks.

Bricks should be stacked no higher than 7 feet; each row should taper back 2 inches for every foot above 4 feet.

Stacked masonry blocks should taper back a half block for each row above 6 feet.

Explain stacking regulations to employees, and paint marks on the wall to indicate the maximum stacking height for specific items.

Strong storage

Never skimp on shelving for the workplace. To reduce the risk of shelves buckling or breaking, choose durable shelving units that have a high load capacity, and post the maximum load amount on or next to each shelving unit.

Even when you have sturdy shelves, injuries can occur when items on shelves aren’t stacked properly or evenly. Inspect shelving areas regularly to ensure items are properly stored. And if employees are using a forklift to remove an item from an upper shelf, they should cordon off the area to prevent other workers from walking through, and the forklift operator should wear a hardhat.

Good guarding

Equipment-contact injuries can occur when machines don’t have adequate guarding. Safeguards should prevent any objects – tools, parts, hands or fingers – from entering the machine. And machines should have a lockout that prevents them from powering-on or moving during inspection or repair.

You can print a checklist that will help you spot possible equipment hazards, such as:

Exposed belts or chain drives

Unguarded moving parts, such as fly wheels and pulleys

Improper electrical grounding

Safeguards that have been tampered with or are inadequately secured

Loose bolts

When you take time to regularly inspect your workplace for hazards, you create a safer environment for your workers. Make sure employees know that they should report unsafe behavior or potential workplace hazards, so you can address those problems right away.