Jane Finlayson, the head of manufacturing at the Employers and Manufacturers Association, has shed light on one of the most dire issues in New Zealand’s battle for improved health and safety. An urgent need exists to solve a billion-dollar harm problem in the manufacturing industry.
Manufacturing safety affects many New Zealanders—10,000 injured workers each year—and over $165 million in ACC claims annually. Workplace harm imposes over $1.23 billion on the economic well-being of New Zealand each year.
The need to develop effective safety solutions has never been more imperative. These numbers bring into sharp focus the enormous physical, emotional, and economic toll workplace harm takes on individuals, families, and businesses. So, what is to be done?
Fortunately, these challenges have solutions. With the implementation of actionable and evidence-based strategies, manufacturers can safeguard their workers and improve overall productivity.
Understanding the Scope of the Problem
Drawing on valuable insights from the EMA’s Project Whakahaumaru and introducing sound practices, this article explores how manufacturers might lead the charges to safer workplaces.
The harm arising from manufacturing is very specific: musculoskeletal injury, mental health issues, respiratory problems, and direct contact with hazardous materials. WorkSafe reports musculoskeletal disorders make up 27% of all manufacturing injuries, while mental health contributes another 17%.
Thirdly, there are groups that are even more at risk, such as older workers and young employees. SMEs also face a particularly daunting task since they typically do not have the resources to deal with complicated regulatory requirements or implement vast safety systems.
Where New Zealand’s workforce constitutes 10% of manufacturing, its coordinated health and safety response has always lagged compared to other industries such as construction and agriculture; hence, this calls for transformative action.
Building a Culture of Safety
One of the key takeaways from Project Whakahaumaru is the importance of fostering a safety-first culture within organisations. Manufacturing safety isn’t just about meeting compliance requirements, it’s about embedding safety into the core values of a business.
Jane Finlayson, EMA’s Head of Manufacturing, emphasises the need for leadership-driven change:
“This isn’t just about compliance; it’s about fostering a culture that prioritises the health and safety of every worker.”
For manufacturers, this means empowering leaders to model and enforce safety practices while engaging employees in ongoing dialogue about risks and prevention strategies.
6 Actionable Solutions for Safer Manufacturing
1. Enhancing training and communication
- Provide workers with intensive training tailored to their specific roles. This includes refresher courses at regular intervals to keep them updated on new safety measures.
- Foster open communication channels, encouraging employees to report hazards or suggest improvements without fear of repercussions.
2. Leveraging technology
- Digital tools like SiteConnect’s manufacturing health and safety management platform can streamline processes such as incident reporting, risk assessments, and compliance tracking.
- Invest in wearable technology to monitor worker health, particularly for roles involving repetitive motions or heavy lifting, to prevent musculoskeletal injuries.
3. Designing safer workspaces
- Conduct ergonomic assessments to minimize physical strain on workers by optimising workstation layouts and providing adjustable equipment.
- Install proper ventilation systems to reduce exposure to harmful chemicals or airborne particles.
4. Addressing mental health
- Recognise the impact of workplace stress and mental health on overall safety. Develop appropriate support systems, such as employee assistance programs, and train managers to identify signs of burnout or distress.
5. Customising solutions for vulnerable groups
- Tailor safety programs to meet the specific needs of older workers and younger employees. For example, older workers may benefit from physical health monitoring, while younger employees may need training in hazard awareness.
5. Promoting early return-to-work programs
- Research shows that injured workers recover faster and more effectively when they return to work in a modified capacity. Collaborate with health professionals to create personalised recovery plans that balance safety with productivity.
The Role of Data in Manufacturing Safety
Accurate data collection and analysis are essential for identifying trends, benchmarking performance, and developing targeted interventions. Safety dashboards are a step forward in this area, providing manufacturers with anonymised, grouped accident data.
By leveraging such tools, businesses can:
- Track injury rates over time.
- Pinpoint high-risk areas or activities within their operations.
- Measure the effectiveness of implemented safety initiatives.
Collaboration for Greater Impact
No single organisation can address manufacturing safety challenges alone. Collaboration among industry groups, regulatory bodies, and technology providers is essential for driving meaningful change. Initiatives like Project Whakahaumaru demonstrate the power of collective action, bringing diverse stakeholders together to design solutions that benefit everyone.
Finlayson underscores the importance of this approach:
“Our commitment to a ‘by industry for industry’ approach is crucial as we work to reduce harm in manufacturing.”
Next Steps for the Manufacturing Sector
To accelerate progress, manufacturers should:
- Engage in safety activities: Participate in such initiatives as Project Whakahaumaru to learn and contribute to improvements in the industry.
- Invest in training and technology: Invest in internal safety expertise development and adopt digital solutions for more operational transparency.
- Adopt proactive practices: Instead of reacting, measures must be preventive, aiming to stop risks before they cause harm.
Conclusion: Manufacturing Safety as a Shared Responsibility
Improving manufacturing safety is both a moral obligation and a business opportunity. Safer workplaces lead to higher employee morale, reduced downtime, and increased productivity. By prioritising health and safety, manufacturers can protect their workforce while fostering long-term growth and sustainability.
As Finlayson aptly states:
“This initiative represents a turning point for the manufacturing sector… Together, we can make a difference.”
With actionable solutions and a commitment to change, the manufacturing industry has the potential to lead the way in workplace safety innovation.
Start your journey with efficient manufacturing safety software.
