What does winning look like in Manufacturing?

My professor once said, "Economies win wars." At first glance, that seems like an oversimplification of what it means to fight a war. But when we dig deeper into that statement, we find it explains nearly every aspect of warfare. When we think of war, we often picture the heroic acts of the men and women on the battlefield. Yet we frequently overlook the larger economic factors that contribute to winning. Every bullet, rifle, and even a tiny screw on a tank plays a crucial role. During the Second World War, manufacturing output increased the GDP by 8%, and American industrial production doubled in just four years (pbs.com). The men and women who gave everything for the war not only defended our nation but also helped strengthen the industrial economy that shaped the United States into what it is today. However, their contributions came at a significant cost. Between 1942 and 1945, the Bureau of Labor Statistics reported over 2 million disabling industrial injuries—including deaths—each year (nps.gov). In response, lawmakers have worked hard to pass legislation aimed at improving worker safety. Yet even today, many of the same challenges persist.

The US manufacturing industry currently employs over 12 million people; however, it also presents a disproportionately high risk for workers. In 2024, the manufacturing sector reported roughly 220,000 workplace injuries and illnesses—the 3rd highest of any industry (ehs.com), and in 2023, nearly 400 manufacturing workers died on the job (bls.gov). Every injury/death is a family affected, and it is important that we continue to make strides in safety in order to ensure that workers, who provide us with our daily essentials, can make it back home safely. It is imperative that when we discuss workplace injuries/death, we do not take the human element out of it. But when we look at an operational cost perspective, OSHA estimates US employers collectively spend almost $1 billion per week on direct workers' compensation costs for injuries (ehsschool.com). When a worker gets injured/dies, it is a lose-lose situation.

With the 2024 OSHA Top 10 out, we see that most manufacturing accidents fall into a few broad categories: being struck by or caught in equipment, falls, overexertion, chemical exposure, and electrical or fire incidents. Notably, these incidents involve two main factors: human error/negligence and unsafe conditions.

So now we are left with this: What does winning look like in manufacturing? Winning can look like a lot of things, but the key is to develop a strong safety program and culture. In order to create long-lasting change, there has to be a shift in culture at your plant. One of the most common questions asked by OSHA during an inspection is, "Who is in charge of safety?" and every employee should be able to confidently and honestly answer, "Me." Safety starts from seasonal workers all the way up to the CEO. Building a safety culture can seem like a daunting task, but it can be broken down into 8 key best practices.

1. Have a strong safety program: A written safety program is the first step in ingraining safety into your plant's culture. However, just having one is not enough; management must actively support and show their commitment to this program. This includes regular training, clear procedures, and accountability. When leadership visibly prioritizes safety, workers know it's serious. Facilities with well-implemented safety programs experience up to 40% fewer injuries (ehsschool.com). This also includes empowering workers to speak up about hazards or near-misses without fear of reprisal.
2. Hazard Identification and Risk Assessment: Regularly inspecting the workplace for hazards—not just via annual audits—is paramount. Doing daily checks and utilizing methods such as Job Safety Analyses (JSAs) or Risk Assessments for each task can prevent injuries. OSHA provides checklists and toolkits for hazard assessments, and modern approaches to Near Miss Reporting can dramatically increase safety.
3. Engineering Controls and Safe Equipment: Whenever possible, engineer out the hazard. This means using machine guarding, interlock systems, automated handling equipment, etc. Preventative maintenance is also key to preventing injuries/deaths. Most importantly, immediately fixing machines when they are unsafe to operate (or taking them out of order) can save many lives. Many injuries happen when guards or alarms are disabled "just to get the job done."
4. Effective training and Qualifications: Human error or lack of knowledge is often an underlying cause in accidents. Ensure all workers are properly trained for their specific jobs—and retrained regularly. Training is not just about how to do the job but how to do it safely: the correct use of machines, PPE, emergency procedures, etc. Simulation and drills can help (e.g., practice emergency stop drills, evacuation drills).
5. Enforce Safety Procedures Consistently: Having the rules posted or on paper is useless if they are not being followed on the floor. Supervision and enforcement are necessary. Conduct safety audits and observations to ensure procedures like LOTO or wearing PPE are actually happening. If shortcuts or unsafe behaviors are observed, correct them through coaching or disciplinary action if needed. Conversely, recognize and reward good safety practices. It is all about creating a culture where the rules are not the enemy. Consistency is crucial: if one shift ignores a rule, it undermines the whole program. Front-line supervisors and team leads need to champion safety daily.
6. Incident Response and Continuous Improvement: Despite our best efforts, incidents will occur, but it does not mean we aren't doing a good job, as there is always room for improvement. Investigate every incident and near-miss to find the root causes and implement fixes. Use methods such as the "5 Whys" and share lessons learned across the organization. Additionally, tracking safety performance metrics to identify trends on a high level can help mitigate future accidents and keep supervisors and workers accountable.
7. Leverage Technology and Innovation: New technologies are offering new ways to enhance safety. Innovation in safety—such as advanced machine guarding systems, real-time monitoring of hazard levels, and data analytics to predict high-risk conditions. Transitioning from paper to digital forms can dramatically increase accuracy in reporting (with incident investigations, near misses, machine maintenance, etc.) and streamline safety performance metrics. It is important that your plant stays current with technology so valuable time and money are not being wasted.
8. Compliance with Standards and Beyond: This last one ties it all back together. Always ensure basic OSHA compliance—this is the baseline of safety. OSHA standards are the bare minimum, but it is important to always strive to be better than the bare minimum. If you complete the previous 7 steps, number 8 is all about bringing it all together. Leveraging all these steps will overwhelmingly exceed OSHA standards and help keep your plant and its workers safe.

Creating a strong safety culture doesn’t happen overnight—it takes months, sometimes years, and it demands constant effort, attention, and buy-in from everyone. The stakes are high, and while the risks are real, every incident and death is preventable. Safety is a shared responsibility. Management has to provide the tools, training, and leadership, but workers also have to stay alert, follow procedures, and look out for one another. It’s not just about checking boxes it’s about protecting people.

We have to shift the mindset from “it’s part of the job” to “how do we make sure this never happens again?” because injuries and deaths are never just part of the job

Building a safety culture means making safety part of the everyday conversation. It means empowering every employee, from seasonal workers to plant managers, to take ownership. It means leadership showing up, not just with words, but with action. It means consistency, accountability, and a refusal to settle for “good enough.”

When safety becomes part of how we work not just something we talk about we start to see real change. And when we work together, stay committed, and keep pushing forward, we can make manufacturing safer. Safety starts with YOU.