Beyond Compliance: Building a Culture of Safety in Modern Manufacturing

• Despite rapid modernization in manufacturing, many factories still rely on outdated safety practices. Why does this gap continue to exist, and what needs to change?

The main aim of modernization in manufacturing is to improve productivity, reduce wastage & quality rejects & improve efficiency. The Human interface and the safety norms associated with this is not growing at the same pace. Productivity and quality enhancement is not integrated into safety standards to include fit, comfort, ease of use  & individual wellbeing. In summary though modernization of machines is happening, safety standards related to PPE modernization are not in place. For eg Hearing validation kits are available to check the fit of a hearing protection device which can also offer better comfort to the user but the use of such validation kits is only part of recommended standards and not compliance. The industry thereby must adopt standards for performance and not only for compliance. Another eg is the use of speech diaphragm in reusable respirator face pieces. This allows the user to communicate in hazardous areas with out removing the face piece. The one thing that can change this dichotomy is strong regulation and enforcement.

• Where do you see the biggest gaps in current safety regulations and their enforcement across India’s manufacturing ecosystem?

Like All other global markets, India has Multinationals, Large and Medium organizations operating in various sectors. The adoption and enforcement of PPE in this segment is fairly high. The reasons could be – exports and hence adherence to higher quality norms, their own work and safety culture & concerns for human life & goodwill. Within this segment the adoption rate for PPE and safety standards may differ within the verticals. Eg Higher standards in Pharma or Oil & Gas companies compared to Textiles, chemicals & mining. One of the biggest components of our manufacturing ecosystem however is small & micro-organizations. They constitute 75% of our workforce. The adoption and enforcement of Safey standards and usage of PPE here is the lowest.

• What are the real-world consequences of these safety gaps—not just from an operational perspective, but also in terms of workforce well-being, productivity, and business continuity

From an operational perspective these gaps result in leading to fatal accidents or disabilities, down time, increase in quality rejects, loss of productivity & absenteeism. Poor safety directly affects employee morale & wellbeing. For eg  Exposure to Welding fumes can potentially cause cancer. However usage of proper powered air respirators can not only reduce the exposure to welding fumes but also increase productivity.  Exposure to long working hours in high noise areas without adequate protection can cause noise induced hearing loss. The use of a simple PPE like Ear plug /Muffs can reduce exposure to high noise with good attenuation. With added feature of communications these ear muffs can actually lead to improved productivity. Not having strong safety awareness about hazards and appropriate PPE, risks people from long term chronic ailments like respiratory & hearing disorders, blindness & loss of limbs.

• How can organizations move beyond viewing safety as a compliance requirement and instead build a strong, embedded culture of safety across the workforce?

We advocate that organizations must not look at safety as a cost but as a strategy. Accident is the cost which leads to loss of human life and brand value / image for the organization. There are many world examples of companies using safety as a differentiated strategy. Eg Shell’s Goal Zero program to reduce downtime & improve trust; Toyota’s Kaizen and Jidoka safety culture leading to fewer incidents & lesser recalls; 3M’s journey to Zero is a program for enhancing safety at workplace across all offices and manufacturing locations. Building a safety culture is a top down process. It benefits not only work places but also everyday life improving the safety culture of our country.

• What role can technology, leadership, and employee awareness play in driving this shift from safety compliance to safety culture?

Safety Training leads to better employee awareness and recognition of Health hazards. This not only leads to proper usage of PPE but a demand for safer workplaces. We have seen many organizations where safety culture is rewarded, recognized & there exists a policy of zero tolerance. Top leaders like CEO’S ,CFO’s & HR heads must shift their view of considering safety as a cost to safety as a strategy. This will create a safer workplace and not restrict the usage only to meet compliance requirements. Technology which makes PPE user friendly and comfortable will be better accepted & used through out the exposure to risks. Safety at workplace is not only the responsibility of the safety officer or department but demands involvement of every stakeholder in the organization.