The crucial role of workwear in improving machine safety: an integrated approach

What’s in a uniform? Much more than corporate branding and cotton. The manufacturing industry relies on teamwear in several ways that go beyond mere aesthetics, with safety being a particularly important but often overlooked intersection.

Risks include injuries resulting from contact with objects and equipment leading causes of work-related deathsphysical protection serves as the first line of defense against workplace hazards. However, the role of work clothing in production safety extends far beyond mere physical protection. It is a crucial part of a complex system of safety measures that includes machine design, workplace protocols and ergonomic considerations.

There is a complicated relationship between workwear and machine safety in production environments. Thoughtful integration can close safety gaps, reduce workplace accidents and ultimately save lives.

Understand the risks of production operations

It’s no secret that production environments entail many risks. The nature of the work performed there – heavy lifting, large-scale and fast-paced machining and exposure to different materials – is inherently risky. Every employer has a dual moral and legal responsibility to protect employees from injury.

The Occupational Health and Safety Association (OSHA) establishes standards for good environmental assessments, employee training, and employee evaluation. It also highlights the importance of personal protective equipment (PPE) – a first line of defense against potential harm if basic safety measures fail.

In most manufacturing facilities, every part of the body is susceptible to injury. Head trauma can result from falling objects or collisions, eye injuries can occur from flying debris or chemical splashes, respiratory problems can arise from exposure to noxious fumes, and hands and fingers can be injured or crushed in machinery. Burns are a constant hazard from hot surfaces, molten materials or exposure to chemicals. Electrical hazards involve the risk of shock or electrocution. Repetitive motion injuries can develop over time due to prolonged use of the machine. Noise-induced hearing loss is common in noisy production environments. Slips, trips and falls remain a persistent hazard due to wet or oily surfaces.

According to OSHAIn 2023, there were 2,074 violations for inadequate eye and face protection. This represented an increase of almost 700 violations compared to the previous year. Respiratory protection is another top 10 violated category, which also saw an increase in the number of violations in 2023.

The intersection of workwear and machine safety

PPE includes all wearables objects or accessories that workers use to protect themselves in the workplace. Safety glasses, earplugs, respirators, gloves and protective footwear each isolate specific body parts from physical and airborne hazards in the hopes of minimizing injuries and deaths on the job.

While personal protective equipment is often sufficient for the safety of healthcare workers, teams in the manufacturing sector need additional safeguards. Machine safety features such as emergency stop buttons, safety screens, light curtains, interlock systems and automatic shutdown mechanisms are designed to prevent worker contact with hazardous parts of the machine or to quickly stop machine operation in an emergency.

The industry has long viewed these two measures as separate measures, with personal protective equipment and machine safety planned in silos. It worked to a certain extent considering that worker The number of deaths in America has steadily declined from approximately 38 fatalities per day in 1970 to 15 fatalities per day in 2022.

But there is much more room for improvement. Gaps remain in worker protections, which are not obvious or necessarily inherent to the specific manufacturing sector. Much of the risk workers face today stems from a lack of attention to how PPE and machine safety features interact.

This siled approach, while effective to some extent, often leaves gaps in employee protection. For example, a machine’s emergency stop button may be out of reach for a worker wearing large protective gloves, or a safety hood may obscure the view of goggles.

Recognizing this limitation, forward-thinking manufacturers and safety experts have begun to advocate for a more holistic approach to workplace safety. They propose that personal protective equipment and machine safety should not be viewed as separate entities, but as complementary components of a unified safety system.

Designing for safety: Integrating PPE considerations into machine design

When properly integrated with machine design and safety protocols, PPE provides a robust defense against the myriad risks present in manufacturing environments. This integration requires a paradigm shift in machine design philosophy. Rather than treating PPE as an afterthought, designers should take it into account from the start.

Employers have a similar responsibility to consider how the PPE they require their staff to wear may interfere with the operation of machines and how machines themselves can be configured to meet PPE requirements. This holistic approach ensures that security measures work together in harmony and do not potentially conflict with each other.

For example, the physical layout of machines should take into account the additional space required for workers wearing protective clothing. Sufficient space around moving parts can prevent accidental contact, even when PPE increases a worker’s profile.

While far from accessible enough to become mainstream, smart PPE promises to revolutionize workplace safety. By using Internet of Things (IoT) connected devices, it facilitates coordination between workers and machines.

Selecting the right work clothing for specific machines

From hard hats and goggles to respirators, gloves and steel-toed boots, all PPE plays a crucial role in protecting workers. While there is no universal “best” PPE solution for all manufacturing environments, there are certain principles that guide the selection process. The nature of the machines, potential hazards and the specific tasks workers perform all influence personal protective equipment choices. American workwear brands stand out for their commitment to quality and durability, essential for effective protection in demanding environments.

For example, when working with cutting machines, cut-resistant gloves are essential. However, these gloves should not be so bulky as to hinder dexterity or increase the risk of entanglement. Likewise, safety glasses for welding work must provide adequate protection against UV rays and flying sparks, while still maintaining good visibility.

It is critical to consider how different PPE components interact with each other and with the machines. For example, a hard hat should be compatible with earmuffs or goggles without compromising its effectiveness. Respirators should not interfere with eye protection or communications equipment.

Regular review and updates of PPE selections are necessary as machines and processes evolve. The OSHA Standard 1910.132 provides guidance on the selection of personal protective equipment, although the input of a qualified safety professional is also invaluable.

How ergonomics affects worker safety in manufacturing

Ergonomics is often wrongly seen as a matter of a pleasant user experience, when in reality it also has a major impact on safety. Comfort and correct use go hand in hand.

Consider a welding helmet with an auto-darkening feature. This ergonomic improvement not only protects the welder’s eyes, but also eliminates the need for constant manual adjustments, reducing neck strain and improving work efficiency. On the machine side, eye-level touchscreen interfaces can replace hard-to-reach buttons, minimizing the need for awkward stretching or bending.

A little forethought goes a long way in mitigating risks.

Proactive risk management

Although machines can be designed with many safety features, they cannot eliminate all risks. Conversely, even the best personal protective equipment cannot compensate for poorly designed or unsafe machinery. The turbulent and complex environments in which production workers work today require a smarter approach risk management. Every employer has a duty and ability to prioritize safety, and from all indications, combining PPE considerations with machine design is the best way to do this.