Introduction
Workplace accidents and injuries in the manufacturing sector are costly and almost unavoidable. Given the enhanced industrialization in the modern world, there has been a rise in workplace-related injuries in manufacturing industries (NIOSH). Surprisingly, most workers and employers in the manufacturing sector lack awareness of the various occupational hazards of their trade. The relevant government authorities and stakeholders in the manufacturing industries have formulated elaborate procedures, activities, policies, and strategies to enhance employee safety. These safety recommendations are known as the Occupational Safety and Health Practices (OSHP) (Lim et al.782). In the United States, the Occupational Safety and Health Administration (OSHA) is responsible for recommending and enforcing workplace safety standards. OSHPs are critical in reducing workplace accidents, injuries, and deaths. Effective implementation of safety standards ensures a healthy environment for employees who, in turn, give their best, thus organizational success. Therefore, this paper examines the major occupational hazards in the manufacturing industry and highlights some of the safety and health practices that stakeholders in the manufacturing industry may apply to enhance workplace safety.
Occupational Hazards
There exist several hazards that may pose health and safety risks to workers in manufacturing environments. Manufacturing industries vary in their operational practices, thus presenting unique safety risks. Despite the operational variations, the manufacturing industry faces similar challenges in addressing workplace safety concerns. Some of the occupational hazards in the manufacturing industry include noise, vibration, falls, machinery-related hazards, radiation, heat, cold, lasers, confined spaces, electrical hazards, chemical hazards, airborne hazards, and sun exposure.
Machinery-related hazards are prevalent in the manufacturing industry and are a leading cause of accidents, injuries, and even deaths. The machine-related hazards include machine guarding and the use of powered industrial vehicles. Machine guarding is a fundamental safety practice in the manufacturing industry. Machine guards protect the operator from rotating parts, hot parts, harmful parts, sparks, and flying objects. Guards provide the last line of defense in the event of errors and laxities on the operator’s part. Despite the extreme importance of machine guarding, poorly guarded machinery exists in many manufacturing facilities. Improperly guarded machinery presents to operators the risk of crushed limbs, amputation, and death in the event of accidents. Employers may alleviate such risks through frequent inspection of machinery to ascertain safety. Machinery operators must ensure that the guards are properly in place before machining (Occupational Safety and Health Administration).
On the other hand, whereas powered industrial trucks in manufacturing plants were intended to enhance operational efficiency, their usage also presents a major occupational hazard. The powered trucks commonly used in manufacturing plants include platform lift trucks, motorized hand trucks, and forklifts. Like most heavy industrial machinery, the safety risks result from improper operation. OSHA recommends elaborate training for operators of these machines to reduce safety risks. Only trained and certified employees should operate powered industrial vehicles.
Noise is a common hazard in the manufacturing environment; it results from machinery involved in the manufacturing processes. Continuous exposure to high noise levels presents the risk of hearing challenges for workers. The prolonged exposure to loud noise numbs nerve endings in the inner ear, which may result in permanent hearing loss. The adverse effects of noise exposure may be mitigated by using proper protective gear, isolating the source, using quieter machines, and limiting employee exposure. OSHA requires employers to limit noise exposure to 8 hours where the noise levels are higher than 85 decibels (Occupational Safety and Health Administration). Noise remains a major hazard that needs to be overlooked.
Vibration is another hazard that is rampant in manufacturing environments. Vibration results from power-driven machinery, equipment, and tools used in manufacturing. Vibrations may be transmitted to workers who operate or work near the equipment producing whole body or hand-arm vibrations. Overexposure to intense vibrations may cause several health complications for workers. The health risks may include back, tendon, joint, and muscle problems. There are currently no OSHA legal standards for limiting exposure to vibrations. However, vibrations may be limited by installing suspension systems to shield equipment operators and isolating vibration sources (Occupational Safety and Health Administration).
Chemical hazards result from the chemicals used in the various industrial manufacturing processes. Chemical substances form an integral part of manufacturing procedures from cleaning products, lubricants, paints, and resins. Industrial chemicals are classified as dangerous or hazardous. Chemicals may explode and cause burns, corrosion, and fire. Inhaling certain chemical substances may lead to respiratory problems. OSHA has developed comprehensive guidance on the handling of chemicals. Employers in manufacturing industries must ensure safe transport, storage, handling, and usage of chemical substances by their employees. Workers should be trained on best handling practices to mitigate risks.
Trips, slips, and falls are major hazards in the manufacturing industry and a leading cause of injuries and fatalities. These accidents arise from debris on floors and work surfaces, wet surfaces, and improper positioning of equipment. Falls often result in injuries and fatalities in extreme scenarios. Workers must keep their workplaces clean; walkaways should be kept clear and free of equipment or debris. Injuries sustained during falls may also be reduced or avoided by wearing protective gear.
Electrical hazards at the workplace include tagout and lockout, electric shock, electrocution, and fire. The hazards often result from unguarded electrical panels, exposed wires, and faulty or improperly installed electrical equipment. OSHA emphasizes electrical training for employers and employees in the manufacturing sector to increase awareness and mitigate these risks. Mechanical, chemical, and electrical energy sources in manufacturing workplaces pose safety risks due to the possibility of lockout or tagout. These risks may be direr during maintenance checks when the machinery may unexpectedly startup or release energy. The unexpected startup or release of energy may cause injuries or fatalities. OSHA recommends that qualified workers use lockout devices to sufficiently de-energize equipment before carrying out maintenance. Adequate personnel training is also vital in mitigating tagout and lockout hazards.
Conclusion
This paper has examined some of the major occupational hazards in the manufacturing industry and provided safety highlights that employers and employees in the manufacturing industry may adopt to enhance workplace safety. OSHA ranks machinery-related hazards such as inadequate machine guarding and poor usage of powered industrial vehicles as the leading causes of accidents, injuries, and deaths in the manufacturing industry. Employers may mitigate the machinery-related occupational hazards through strict enforcement of OSHA regulations and adequate personnel training. The effects of noise, a rampant yet often ignored occupational hazard, may be addressed by isolating noise sources, using proper gears, mufflers, and limited exposure. Suspension systems and isolation of sources may control vibrations. Training personnel is key to sensitizing them on the safe transportation, storage, handling, and usage of chemicals. Electrical hazards may be mitigated by ensuring proper electrical equipment installation and training of employers and employees. Ensuring clean workspaces is key to reducing trips, slips, and falls caused by dirty, wet, and uncleared surfaces or floors. There is a need for more meaningful collaboration between relevant government agencies, employers, and employees to ensure safe and healthy manufacturing environments devoid of risks and hazards.
Works Cited
Lim, Hui Yee, and Hussein Mohammed Abu al-Rejal. “Occupational safety and health practices in manufacturing industry.” (2017): 782-792.
Occupational Safety and Health Administration (OSHA). “Occupational Noise Exposure.” United States Department of Labor, United States Department of Labor, 2022, https://www.osha.gov/noise#:~:text=With%20noise%2C%20OSHA’s%20permissible%20exposure,dose%20is%20cut%20in%20half.
Occupational Safety and Health Administration (OSHA).”Industry-Specific Resources.” United States Department of Labor, United States Department of Labor,2022, https://www.osha.gov/complianceassistance/industry
The National Institute for Occupational Safety and Health (NIOSH). “Manufacturing Program: Occupational Safety and Health Risks.” Center for Disease Control and Prevention, n.d. https://www.cdc.gov/niosh/programs/manuf/risks.html
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