Running a manufacturing facility is a balancing act between keeping things running smoothly and making sure everyone stays safe. When safety takes a backseat, the results can be serious—injuries, fines from OSHA, more workers’ compensation claims, and higher insurance costs. But when safety is done right, it can actually give a company an edge over competitors.
Eddie Dreyer, a commercial lines underwriter at Central Insurance, points out that many manufacturers often put production before safety. This creates an environment where OSHA violations are common. He stresses that safety needs to be more than just a sign on the wall—it has to be a consistent focus all year long.
Among the most common problems in manufacturing are improper machine guarding, lockout/tagout (LOTO) failures, lapses in personal protective equipment (PPE), poor hazard communication, and material handling or forklift injuries. Machine guards are there for a reason: to keep workers safe from dangerous parts of machines. Yet, sometimes guards get removed or bypassed to speed up work, increasing the risk of accidents. Dreyer advises keeping all guards intact, training workers on their importance, and regularly checking the equipment.
LOTO failures happen when machines are not properly shut off during maintenance, which can lead to serious injuries or worse. Dreyer highlights that skipping steps during busy times can be deadly. Training everyone—not just maintenance workers—and following clear procedures can help avoid these risks.
PPE is another area where things can slip. When supervisors don’t enforce its use or equipment is damaged or missing, workers get the message that safety isn’t top priority. This can raise injury rates and insurance costs. Dreyer suggests making sure all staff have the right PPE, checking it daily, and having supervisors lead by example.
Hazard communication, especially about chemicals and dangerous materials, also needs attention. Proper labeling, storage, and ongoing training are crucial. Smaller operations might struggle to keep up, but involving safety committees and regularly auditing storage can stop problems before they start.
Forklift accidents cause many injuries and deaths every year. Risks increase when operators cut corners, lack proper training, or when walkways and lanes aren’t clearly marked. Dreyer recommends yearly certification for forklift drivers and using visibility aids like horns and mirrors to improve safety.
Stopping OSHA violations isn’t just about ticking boxes. It requires building a safety culture where workers care about their own safety and management stays committed to long-term wellbeing over quick production gains.
Central Insurance offers experience and guidance to manufacturers looking to protect their teams and their business. With nearly 150 years in the field, they provide tailored coverage, fast claims service, and risk management support. Manufacturers can work closely with local independent agents to find the right coverage and build safer operations.
Taking these steps not only keeps teams safe but also helps manufacturers avoid costly penalties and maintain their good standing with insurance providers. In the end, safety and productivity can work hand in hand when both are given the attention they deserve.