The safety of industrial finishing production lines is a constant concern for the heads of plant managers. They are dealing with hazardous materials and people on a daily basis. Almost everything on production lines can pose a hazard.
The scope of this article is to identify threats so everyone involved can avoid them. Also, provide resources for industrial finishing plants to increase safety for good.
Why is safety important in industrial finishing production lines?
By taking steps to improve safety, companies can protect their workers, prevent accidents, and maintain a good reputation. We have plenty of reasons to improve safety in industrial finishing production lines.
To protect workers from injury and illness: Industrial finishing production lines can be dangerous places, with a variety of hazards present, such as toxic chemicals, flammable materials, and moving machinery. Without proper safety measures in place, workers are at risk of serious injury or illness.
To prevent accidents and property damage: Accidents can happen at any time, but they are more likely to occur in a hazardous environment such as an industrial finishing production line. Accidents can lead to serious injuries and fatalities, as well as damage to property and equipment.
To comply with regulations: Most countries have regulations in place that govern safety in industrial workplaces. These regulations are designed to protect workers from hazards and prevent accidents. Strict compliance with codes and standards coupled with robust safety programs greatly reduces the considerable risks present in industrial finishing. This protects both workers and facilities. Also, it protects companies from fines and other penalties.
To maintain a good reputation: A company that has a good safety record is more likely to be seen as a reliable and trustworthy partner. This can be beneficial when attracting new customers and partners.
In addition to these general reasons, safety is also important in industrial finishing production lines because of the specific nature of the work. For example, industrial finishing often involves the use of toxic chemicals and flammable materials. If these materials are not handled properly, they can pose a serious risk to workers and the environment.
Industrial finishing production lines also typically involve the use of a variety of machinery. If this machinery is not properly guarded or maintained, it can pose a risk of entanglement or other injuries.
Common hazards in industrial finishing production lines
Industrial finishing production lines can be dangerous places, with a variety of hazards present.
Toxic chemicals: Many industrial finishing processes involve the use of toxic chemicals, such as solvents, paints, and coatings. These chemicals can be inhaled, absorbed through the skin, or ingested, and can cause a variety of health problems, including respiratory problems, skin irritation, and cancer.
Moving machinery: Industrial finishing production lines typically involve the use of a variety of machinery, such as conveyor belts, spray guns, and ovens. This machinery can pose a risk of entanglement, crushing, or other injuries.
Overhead hazards: Overhead conveyors, process pipes, cranes, etc. pose impact hazards to workers below. Signage and hard hats should be required.
Flammable materials: Flammable vapors and mists from solvents, paints, etc. can ignite in spray booths, ovens, and other areas. Proper ventilation, grounding, bonding, and eliminating ignition sources are critical.
Slips, trips, and falls: Overspray residue builds up on floors, platforms, ladders, etc. creating slippery surfaces and fall hazards. This can increase the risk of slips, trips, and falls, which can lead to serious injuries.
Noise: Finishing equipment like spray booths creates noise levels >85 dB requiring hearing protection. This can lead to hearing loss, tinnitus, and other health problems.
Ergonomic issues: Repetitive motions, frequent bending, lifting, and prolonged standing during finishing can cause strains and sprains.
Electrical hazards: Improperly grounded or faulty electric systems, tools, and lighting pose shock risks especially around solvents.
Confined spaces: Tanks, booths, and other confined areas require precautions for safe entry and exit.
Waste accumulation: Combustible dust from sanding and improper chemical storage increase fire risks. Good housekeeping is a must.
Resources for improving safety
There are a number of resources available to help businesses improve the safety of their industrial finishing production lines. Prioritizing worker safety protects both human health and the company’s bottom line.
These resources provide great guidance for developing robust finishing line safety programs. They include government agencies, industry associations, safety consultants, equipment manufacturers, and more.
Government agencies
Many government agencies have resources available to help businesses improve safety in the workplace. For example, the Occupational Safety and Health Administration (OSHA) in the United States has several resources available on its website, including publications, training materials, and compliance assistance.
Occupational Safety and Health Administration (OSHA): OSHA has specific standards for surface finishing operations (29 CFR 1910.94) and spray finishing (29 CFR 1910.107) covering ventilation, PPE, electrical, fire protection, training, etc. The OSHA’s Industrial Finishing Guide provides information on the hazards present in industrial finishing operations and how to mitigate them.
National Fire Protection Association (NFPA): This organization develops and publishes fire safety standards and codes. Relevant NFPA codes include NFPA 33 Spray Application Using Flammable or Combustible Materials and NFPA 70 National Electrical Code.
Industry associations
Many industry associations also have resources available to help their members improve safety. For example, the National Association of Manufacturers (NAM) in the United States has a few resources available on its website, including publications, training materials, and best practices.
NAM’s Safety Center: This website provides a variety of resources on safety in the workplace, including publications, training materials, and best practices.
American Society of Safety Engineers (ASSE): This professional organization offers a variety of resources on safety in the workplace, including training, certification, and publications.
National Paint & Coatings Association (NPCA): This trade association offers a variety of resources on safety in the paint and coatings industry, including training materials and compliance assistance.
Safety consultants
There are a number of private safety consultants who can help businesses improve safety in the workplace. These consultants can assess a business’s safety program and identify areas for improvement. They can also provide training and assistance in implementing new safety procedures and protocols.
Risk assessments: External consultants who conduct routine comprehensive assessments to identify hazards and required risk controls.
Training programs: External training companies that provide extensive onboarding and ongoing training to workers on equipment, chemicals, policies, PPE, and safe practices
Ventilation expertise: External experts on industrial hygiene to design, install, and test spray booth ventilation and exhaust systems.
Equipment manufacturers
Many equipment manufacturers also have resources available to help their customers use their equipment safely. These resources may include training materials, safety guides, and checklists.
Manufacturer SDS: Safety Data Sheets from chemical/equipment manufacturers provide guidance on proper use, PPE, storage, and hazards. Each manufacturer produces its own SDS.
Other resources
There are still other internal resources that any industrial finishing company can develop to increase its safety.
Audit checklists: Use checklists during audits to regularly inspect conditions, verify compliance, evaluate risks, and identify safety improvements.
Safety committees: Teams comprised of leadership, engineers, and workers can spearhead safety initiatives and address issues.
PPE programs: Supply appropriate PPE for each job, train workers on proper use, and mandate consistent utilization per company policy.
Warning signs/procedures: Post hazard signage and establish special operating procedures for high-risk processes.
How to improve the safety of industrial finishing production lines
Many actions can be put in place to improve the safety of industrial finishing companies. Let’s consider a few.
Implement proper training and education: All employees working on an industrial finishing production line should be properly trained in the safe operation of all equipment and materials. They should also be educated about the potential hazards of the job and how to avoid them.
Use appropriate safety equipment: All employees should be provided with and required to wear appropriate safety equipment, such as personal protective equipment (PPE), like gloves, goggles, and respirators.
Implement proper safety procedures and protocols: There should be clear and concise safety procedures and protocols in place for all operations on the production line. These procedures should be regularly reviewed and updated to ensure that they are effective and up to date.
Maintain equipment properly: All equipment on the production line should be properly maintained and inspected on a regular basis to identify and address any potential safety hazards.
Have a plan in place for emergencies: There should be a plan in place for responding to emergencies, such as fires, spills, and medical emergencies. All employees should be trained in the emergency plan and their role in it.
Some additional actions that can be taken
Safety is extremely important in industrial finishing production lines. Any action you can take, even when it looks unimportant, plays a role in keeping everyone safer.
- Encourage employees to report any safety concerns to their supervisor immediately
- Conduct regular safety inspections of the production line and identify and address any potential hazards
- Reward employees for following safety procedures and protocols
- Promote a culture of safety in the workplace.
Benefits for improving safety of industrial finishing production lines
Improving safety for industrial finishing production lines provides many important benefits:
Reduced risk of worker injury and illness: The most important benefit of improving safety is to protect workers from injury and illness. By implementing safety procedures and protocols, providing workers with proper training and education, and using appropriate safety equipment, manufacturing companies can reduce the risk of workers being injured or becoming ill on the job.
Reduced risk of accidents and property damage: Accidents can happen at any time, but they are more likely to occur in a hazardous environment such as an industrial finishing production line. Accidents can lead to serious injuries and fatalities, as well as damage to property and equipment. By improving safety, production companies can reduce the risk of accidents and protect their property and assets.
Improved compliance with regulations: Most countries have regulations in place that govern safety in industrial workplaces. These regulations are designed to protect workers from hazards and prevent accidents. By complying with safety regulations, metalworking companies can avoid fines and other penalties.
Improved employee morale and productivity: When employees feel safe at work, they are more likely to be productive and engaged in their work. Improving safety can also help to reduce absenteeism and turnover rates.
Enhanced company reputation: An organization that has a good safety record is more likely to be seen as a reliable and trustworthy partner. This can be beneficial when attracting new customers and partners.
Improving the safety of industrial finishing production lines has many benefits for production companies, both in the short and long term. In addition to these general benefits, there are also specific benefits to improving safety in industrial finishing production lines, like:
- By reducing the risk of fires and explosions, companies can save money on insurance costs
- By reducing the risk of worker injuries, production companies can save money on workers’ compensation costs
- By improving compliance with safety regulations, manufacturing companies can avoid fines and other penalties.
Improving the safety of industrial finishing production lines is worth the time and effort. We have been helping companies increase the safety of their welding, cutting, automation and industrial finishing operations for several decades. In fact, it’s part of our mission. Don’t hesitate to contact us to help you too.
