The challenges of finding and maintaining skilled labor, controlling costs and maximizing production efficiency are constants in the world of manufacturing. From a business standpoint, workplace accidents significantly add to these challenges by impacting the availability of workers, increasing costs via replacement labor and repairs to damaged equipment, and decreasing productivity to manage the accident scene, which may require prolonged shutdowns and OSHA inspections. Additionally, no employer wants to endanger their workers, especially with a preventable risk.
When thinking of workplace accidents in manufacturing, falls are not often at the top of the list, which could be a costly oversight. This article will share insight into the importance of addressing fall prevention in manufacturing and provide actionable steps to mitigate the risks.
The cost of falls in the workplace
Fall injuries in manufacturing have a greater likelihood of resulting in a lost workday claim and are 56% more expensive than the average workers’ compensation (WC) claim in manufacturing. [1]
According to OSHA data from 2022-2023, citations due to falls carry the costliest penalties of all citations in the industry, averaging $6,519 per citation. [2] The fact is, despite technological advancements and strictly enforced safety measures, falls remain a significant concern, and manufacturers must prioritize fall prevention as a key safety initiative.
Marcello Presutti, Nationwide's underwriting expert in manufacturing, emphasizes, "The cost of falls goes beyond the immediate medical expenses. Falls are preventable and can have adverse impacts on the morale of the workforce and potentially lead to long-term financial impact for the business."
Types of falls
Falls from same level
Just because a manufacturer hasn't experienced a fall claim doesn't mean their facility and workforce are safe, especially when common causes include:
- Uneven flooring, elevation changes, and damage to floor
- Presence of water, oil or grease on the floor
- Foreign substances such as plastic sheeting, packing material and extension cords
Falls from heights
Falls from ladders and elevated work surfaces are particularly hazardous. These incidents often result in severe injuries and higher claims costs. Proper safeguards, compliant physical barriers and active fall protection measures are essential to mitigate these risks.
Actionable steps for fall prevention
Implementing an effective fall prevention strategy requires a comprehensive approach. Here are 7 actionable steps to improve fall prevention in manufacturing facility:
- Establish a culture of safety.
When safety is modeled by leadership and expected of everyone, it becomes part of the fabric of a manufacturer’s workplace. Everybody has a role to play in keeping themselves and their teammates safe. Create a safety committee, correct unsafe behaviors and instill a team approach to safety.
- Conduct a comprehensive risk assessment.
Inspect work surfaces, stairways and platforms to identify potential fall hazards. Regular evaluations of physical conditions, maintenance programs, and work practices are crucial to ensuring a safe work environment. Use resources such as Nationwide's slips, trips and falls evaluation form to guide this assessment.
- Implement and enforce strict safety protocols.
Establish clear safety protocols that include safe work practices, such as using designated walkways and the use of personal protective equipment (PPE) for all workers. Ensure that these protocols are communicated effectively and enforced consistently.
Marcello Presutti notes, "In addition to a culture that puts employees' safety first, clear communication and enforcement of safety protocols are key to preventing falls and ensuring a safe workplace."
- 4. Provide regular safety training.
Regular safety training is essential to keep employees informed about fall prevention, hazard recognition and proper use of equipment and machinery. If applicable, consider developing a special program for temporary workers who are unfamiliar with the facility. Incorporate training sessions that emphasize key safety practices, such as maintaining 3 points of contact when climbing ladders.
- Invest in safety equipment and technology.
Investing in safety equipment such as guardrails, platform ladders and anti-slip flooring can significantly reduce fall risks. Additionally, explore new technologies and solutions that enhance workplace safety.
- Review and update fall prevention strategies.
Regularly review and update the fall prevention strategy to incorporate new technologies, regulations and best practices. Stay informed about industry trends and advancements that can help improve safety measures.
- Leverage Nationwide's Loss Control Services.
Nationwide offers a range of loss control services and resources designed to help manufacturers mitigate fall risks. Nationwide provides valuable support to enhance fall prevention efforts, including expert consultations and access to the latest safety guides.
Phillip Maddox, Nationwide's loss control expert in fall prevention, advises, "Utilizing Nationwide's loss control resources can provide manufacturers with the tools and knowledge needed to create a safer work environment and reduce the risk of falls for their employees."
Prioritizing fall prevention
Fall prevention in manufacturing is not just a regulatory requirement; it's a critical aspect of maintaining a safe and productive workplace. By prioritizing fall prevention, manufacturers can protect their workforce, reduce costs and ensure operational continuity. Don't wait for an accident to happen. Take proactive steps today to safeguard manufacturing facilities and employees.
For more information on preventing falls in manufacturing, visit Nationwide’s Loss Control Services today.
Sources:
[2] “Frequently Cited OSHA Standards Results,” osha.gov/ords/imis/citedstandard.naics (accessed Sept. 11, 2024).