Common challenges with fall protection in indoor industrial settings and tips to keep employees safe (and stay OSHA-compliant)
It’s no surprise that a lack of appropriate fall protection is consistently the most cited OSHA violation in the construction industry, but indoor industrial environments (i.e. manufacturing) require fall protection as well, but are often overlooked or misunderstood.
Manufacturing has its fair share of fall, trip and slip hazards due to anything from uneven walkways to greasy work surfaces. This blog addresses four common challenges associated with proper fall protection in a manufacturing environment and best practices when it comes to keeping your employees safe.
Indoor Fall Protection Hazards in Manufacturing
The need for fall protection is most often associated with falls from heights. While heights do need to be addressed, the majority of fall hazards in a manufacturing workplace are not elevated. Some common manufacturing fall hazards include dangerous equipment, uneven walking surfaces and clutter or mess on the floor.
Manufacturing equipment like heavy machinery has the potential to cause a devastating injury if an employee trips or stumbles into it. It’s crucial that employers provide proper fall prevention and keep work areas free of clutter to avoid these kinds of mishaps. There are many steps you can take to keep your workplace as safe as possible and up to OSHA standards.
While slips, trips and falls may all result in serious injuries, OSHA defines them differently.
Slips: A loss of balance as a result of limited traction between shoes and the walking surface
Trips: A loss of balance caused by forward momentum after a foot hits an object
Falls: A loss of balance as a result of movement outside the center of gravity
Manufacturing Safety Tips
1. Keep the Floor Clear
Keeping aisles, walkways and equipment lanes free of inventory, materials and supplies is crucial to prevent trips and falls. Properly stacking boxes and other containers minimizes the risk of stumbling over clutter. Good housekeeping habits should be ingrained in company culture, with regular inspections to identify and address any clutter that could pose a danger. Cleanliness and organization not only protect employees but also prevent increased insurance costs and regulatory citations.
Spills, whether from water, grease or debris, can make warehouse floors dangerously slippery, increasing the risk of falls. Addressing these issues promptly is essential for maintaining a safe work environment. Maintaining drains can help reduce standing water, and cleaning up spills immediately in areas without drainage is crucial. Dry spills from sawdust or other materials can be just as hazardous as wet spills and equal precaution should be taken. Additionally, using signage and other warnings to alert workers to slippery conditions can prevent accidents.
2. Install Proper Lighting
Poor lighting is often a direct cause of fall accidents in indoor industrial settings, as it can obscure potential hazards and create dangerous shadows. By keeping work areas well-lit with good quality lighting that minimizes glare and shadows, you help employees to clearly see their surroundings, reducing the risk of trips and falls. This not only assists workflow but also prevents eye fatigue and headaches, significantly enhancing workers’ health and productivity.
The optimal lighting solution for a warehouse should balance daylight and artificial light, providing flexibility and energy efficiency. Proper lighting should be installed in walkways, staircases, hallways and basements. It’s also crucial to turn on lights before entering darkened areas and to promptly repair or replace any malfunctioning switches or cords.
In 2020, there were 12,910 reported injuries from falls on the same level (non-elevated) in the private manufacturing industry. In the same year, there were 55 reported deaths from falls, trips and slips. (Bureau of Labor Statistics)
3. Use the Correct Fall Protection Systems
Regardless of height, if a worker could fall into dangerous machines or equipment, such as vats of acid or conveyor belts, employers must provide safety railings and toeboards to prevent injuries.
On loading docks, where trucks are constantly arriving and departing, and heavy equipment is in motion, fall safety mitigation should include:
- Guardrails around exposed edges
- Safety gates to minimize entry and protect against falls
- Bright contrasting warnings on steps and ledges
- Flashing lights or warning signs to alert employees to potential dangers
Stairways in a manufacturing facility pose fall risks as well, especially when employees are carrying tools or supplies while ascending or descending. To enhance stairway safety and ensure OSHA compliance, it is important to provide adequate lighting, keep stairs clear of obstructions and debris, install handrails, and use safety gates at stairway entries to prevent unexpected falls.
Regular inspection, maintenance and evaluation of fall protection equipment is essential to ensure it remains effective and safe for use. Using the highest-quality equipment and ensuring it meets OSHA standards will greatly enhance the safety of your manufacturing environment.
4. Provide Adequate Training
Proper training is a cornerstone of preventing fall-related injuries in any work environment. Training workers about job hazards and in a language they understand is crucial, as the best safety practices are ineffective if employees are insufficiently trained. New hires require thorough onboarding to grasp the dangers inherent in their work environment, especially in factories and plants where hazardous chemicals and complex machinery are common. However, safety training shouldn’t be limited to new employees; it must be an ongoing part of each worker’s employment. Maintain open lines of communication to ensure employees are aware of important safety practices and know how to maintain them effectively.
Go Above and Beyond for Safer Manufacturing
At EDGE Fall Protection, our first priority is the safety of your employees. Even after all OSHA’s finable regulations are met, there are more steps that can be taken to maximize the safety of your workplace. Partner with EDGE to find the optimal solution for your unique fall protection needs with the help of experts who care. Contact us today at 844-314-1374.
