Industry 4.0 has irrevocably changed manufacturing production, enabling it to rapidly evolve and become increasingly interconnected. Despite substantial innovations in manufacturing and significant industry advancements, physical risks persist. By addressing and mitigating physical risks, businesses directly enhance human sustainability, protecting their employees from harm.
The 2024 International Labour Organization (ILO) report highlights that agriculture, construction, forestry, fishing, and manufacturing collectively have 200,000 fatal injuries each year and represent 63 per cent of all fatal occupational injuries. Of all regions, the ILO estimates that two-thirds (65 per cent) of global work-related mortality happens in Asia.
United Nations Global Impact defines occupational safety and health (OSH) as creating a safe and healthy work environment by actively preventing work-related injuries and diseases and promoting workers’ health. Manufacturers must actively manage physical risks to ensure a safe and efficient production environment. But what are the most common risks within manufacturing?
Smart manufacturing can reduce physical risks
According to the ILO, physical hazards include “noise, vibrations, radiation, electricity, and extreme temperatures.” For example, loud noise in the workplace gradually damages workers’ hearing when management fails to notice it until the combined effects of noise exposure and age-related hearing loss become apparent. Innovative solutions actively address these risks, preventing accidents, reducing downtime, and ensuring compliance with safety regulations.
Industry 4.0 and smart manufacturing enable manufacturers to reduce physical risks and improve worker safety. Smart manufacturing refers to the integration of advanced manufacturing technologies, data analytics, artificial intelligence (AI), machine learning, digital twins, and the Internet of Things (IoT) into the manufacturing process. This integration creates a more connected, automated, and flexible production system.
As these technologies improve operational productivity, they can also uplift industrial safety efforts in the following ways.
Employ automation for hazardous tasks
Integrating automation into your manufacturing processes is not just a trend but a strategic necessity in today’s competitive landscape. Manufacturing Digital highlights that robots and automated systems can effectively take over hazardous tasks previously done by human workers. Specifically, these advanced solutions can:
- Manage tasks involving hazardous materials, such as flammable chemicals or explosive substances.
- Operate seamlessly in extreme environments, including areas with high temperatures.
- Perform physically demanding and high-risk operations, like lifting and moving heavy loads at great heights.
A recent study underscores the positive impact of employing robots to reduce industrial injuries. The findings reveal that increasing robot exposure by one standard deviation (1.34 robots per 1000 workers) can lower work-related injury rates by 1.2 injuries per 100 full-time workers. This data is driving forward-thinking manufacturers, like Mercedes-Benz, to harness the power of automation and robotics to enhance workplace safety.
For instance, Mercedes-Benz is currently testing a 172 cm humanoid robot designed to handle tasks such as placing heavy boxes (up to 25 kg) on shelves—tasks that pose significant injury risks to human workers. Additionally, smart manufacturing can unlock a higher level of employee safety.
Real-time monitoring can improve safety outcomes
Manufacturing Digital indicates that smart manufacturing enhances safety by providing real-time insights into potential hazards and adopting advanced safety protocols and technologies to prevent accidents and injuries. By integrating automated safety systems, such as emergency stop buttons and real-time hazard detection sensors, businesses create safer working environments.
Automated safety barriers protect workers from moving machinery, while sensors and monitoring systems detect dangers and alert workers before they encounter harmful substances, significantly reducing the risk of accidents and injuries. For example:
- Live gas monitors (e.g., for carbon dioxide, carbon monoxide, chlorine) can reduce exposure to hazardous gases.
- Air quality sensors can notify workers and managers if the air quality falls below safe levels.
- Moisture sensors and temperature transmitters can identify steam leaks and hazards from high-pressure or high-temperature systems.
Businesses must also train staff on these risks while integrating smart manufacturing and innovation to prioritise safety effectively.
Offer training programs and workforce education to mitigate physical risks
Developing comprehensive training programmes is essential for fostering a robust safety culture in smart manufacturing. Businesses must ensure employees are proficient in safely operating new technologies and machinery through hands-on practice with the latest equipment and conducting simulation drills for emergency situations. Regular updates and refresher courses are vital to keeping everyone informed about the latest safety practices, ensuring they maintain workplace safety standards.
While workforce education is fundamental for mitigating physical risks, it’s equally critical to observe how these strategies are put into practice by industry leaders. One exemplary case is Rolls Royce’s Zero-Harm policy, which demonstrates how prioritising safety can enhance operational performance.
Zero-Harm policy: The Rolls Royce case study
“Whenever we have a conversation about industrial safety, there seems to be an implicit misunderstanding that it gets in the way of productivity. However, the truth is that safety practices can actually help better understand and improve the performance of operations,” says Akhilesh Pandey, Head of Health, Safety, Environment and Well-Being, Asia-Pacific, Rolls-Royce.
Pandey highlights how smart manufacturing is revolutionising production and safety protocols at Rolls-Royce. By leveraging advanced safety devices, workers gain access to valuable insights that were previously unavailable. These smart safety devices generate and access safety data, providing new perspectives on operational issues. This data creates a “trail of bread crumbs,” revealing underlying problems that impact production.
At Rolls-Royce, worker safety and well-being are integral to the company culture. The Zero-Harm policy, a five-part model, encourages employees to adopt a proactive mindset and spirit towards safety. Amidst rapidly evolving technologies, regulations, and processes, this model underscores that a reactive approach is insufficient. To uphold the highest safety standards, Rolls-Royce offers a comprehensive source of information, enabling employees to access a wide range of guidance and tools across the business.
Emerging technologies can help manage the dangers of physical risks in manufacturing
Amid rapid advancements in smart manufacturing, companies must recognise employees as their most valuable asset. Prioritising employee health and safety not only boosts morale but also enhances productivity and efficiency. Leveraging technology transforms safety into a strategic advantage, allowing manufacturers to achieve consistent safety outcomes both internally and throughout their broader ecosystem.
Leverage resources like the Smart Industry Readiness Index (SIRI) to evaluate the expertise and technologies needed to mitigate physical risks. By using this tool, you can develop effective Industry 4.0 transformation strategies. Integrate SIRI with your existing safety measures to strategically plan your Industry 4.0 journey and ensure long-term success in a dynamic manufacturing landscape while prioritising employee safety.
