Power Up Your Protection: 10 Health & Safety Tips for Manufacturing

The manufacturing sector is the backbone of the economy, but it also carries some of the highest health and safety risks. From heavy machinery to hazardous materials, protecting your people is not just a legal duty—it's the core of a smart, efficient, and ethical operation.

Ready to shift your safety programme from reactive to proactive? Here are 10 non-negotiable health and safety tips for every manufacturing business:

1. Machine Guarding is King

Moving parts, gears, belts, and rotating shafts are major amputation and entanglement risks. Always ensure all machinery is properly guarded.

• Tip: Machine guards should be secure, well-maintained, and prevent any part of an employee's body from reaching a danger zone while the machine is operating. Never allow production targets to compromise the integrity of a guard.

• Make sure your PUWER assessments are done by a competent person (i.e. not any old staff who may know nothing about PUWER and the technical standards)

  

  
  

2. Implement a Rigorous Lockout/Tagout (LOTO) Procedure

Maintenance, cleaning, or repair work on machinery requires the control of hazardous energy (electrical, mechanical, hydraulic, etc.).

• Tip: Train all employees who service or maintain equipment on LOTO procedures. This system ensures that equipment is completely de-energised and locked before work begins, preventing unexpected start-up that can be fatal.

• An alternative method is the LOTOTO Lock Out, Tag Out, Try Out, which includes a test to check the system is isolated and disabled, and should be used on higher risk equipment / processes.

  
  

3. Prioritise Slips, Trips, and Falls Prevention

Wet floors, oil spills, and cluttered walkways are the number one cause of non-fatal injuries across all industries, and manufacturing is no exception.

• Tip: Enforce excellent housekeeping. Clean up spills immediately, keep cables and hoses clear of aisles, and ensure all work areas are well-lit. Use non-slip mats in areas prone to wetness or oil residue.

  
  

4. Manage Hazardous Substances (COSHH)

Many manufacturing processes involve chemicals, solvents, dust, or fumes that can be harmful if inhaled or touched. This falls under the Control of Substances Hazardous to Health (COSHH) regulations.

• Tip: Conduct thorough COSHH assessments. Provide clear safety data sheets (SDS), ensure proper ventilation (Local Exhaust Ventilation - LEV), and store chemicals correctly in marked containers. Substitute hazardous materials for less harmful ones whenever possible.

• Ensure your staff know what they are using, the hazards of it, and the controls in place.

  
  

5. Don't Underestimate Noise and Vibration

Prolonged exposure to high noise levels from machinery can lead to permanent hearing loss. Hand-arm vibration from tools can cause nerve and circulatory damage. The HSE are focussing heavily on noise at the time of writing this article, and we suspect manufacturing businesses will be in their sights.

• Tip: Conduct noise and vibration assessments. Implement engineering controls (like isolating noise sources) first, provide and enforce the use of appropriate Personal Protective Equipment (PPE), such as earplugs or earmuffs.

• Focus on controlling noise and vibration at its source, PPE is not a long term solution.

• The HSE (Health and Safety Executive) promotes the CUFF system to ensure effective management of personal hearing protection in noisy workplaces, where CUFF stands for Condition, Use, Fit the ear, and Fit for purpose.

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6. Demand the Correct Use of PPE

PPE is the last line of defence, but a critical one. This includes safety glasses, hard hats, high-visibility vests, steel-toe boots, and appropriate gloves.

• Tip: Provide the correct PPE for the specific task and make its use mandatory. Regularly inspect PPE for wear and tear, and train staff on how to properly wear, care for, and store their gear.

  
  

7. Focus on Manual Handling and Ergonomics

Repetitive tasks, heavy lifting, and awkward postures are common in a factory environment, leading to musculoskeletal disorders (MSDs) like back pain and carpal tunnel syndrome.

• Tip: Assess all manual handling tasks. Provide mechanical aids (forklifts, hoists, conveyor belts) where possible. Train staff in safe lifting techniques and rotate tasks to avoid prolonged, repetitive strain.

  
  

8. Invest in Comprehensive and Ongoing Training

Safety knowledge shouldn't be a one-time induction. Employees need to be kept up-to-date on risks, new procedures, and machinery.

• Tip: Make training job-specific. Use a mix of practical demonstrations, visual aids, and regular 'toolbox talks' before shifts start. Ensure new or agency staff receive the same high standard of instruction as veteran employees.

  
  

9. Encourage Hazard Reporting and Near-Miss Analysis

A strong safety culture relies on employees feeling safe to report risks without fear of blame. Near-misses are invaluable data points that highlight a potential accident waiting to happen.

• Tip: Create an easy, anonymous process for reporting hazards and near-misses. Treat every report as an opportunity for improvement, and communicate the resulting corrective actions back to your team.

  
  

10. Regularly Inspect and Maintain Equipment

Machinery that isn't maintained is a safety hazard waiting to fail. This includes everything from forklifts and welding gear to fire extinguishers and electrical systems.

• Tip: Establish a schedule for preventative maintenance. Keep detailed records of all inspections and repairs. Ensure only competent, authorised personnel are permitted to service and operate the equipment.

  
  

By building these 10 principles into your daily operations, you will not only meet your legal requirements but also create a workplace where employees feel valued, resulting in higher morale, fewer incidents, and a more productive business overall. Safety is always a sound investment.

If you need further advice or support on any of the health and safety topics above LESH would be happy to help you! Get in touch.