Preventing the Preventable: A Modern Approach to Health and Safety in Manufacturing 

As the United States sees a resurgence in manufacturing and the onshoring of manufacturing jobs, companies are refocusing on their health and safety programs. From physical injuries on the job, environmental hazards, repetitive motions, and lifting heavy objects, the risks are real and constant, as are the rising healthcare costs associated with them. To diminish these risks and strengthen the bottom line, manufacturing workplaces must go beyond traditional safety measures and adopt more comprehensive occupational health solutions. 

So, what exactly does this look like? Historically, the approach to workplace safety in manufacturing has been largely reactive, addressing hazards after they arise. For example, if an employee strained their back lifting a heavy object, the typical solution might involve immediate first aid and perhaps revisiting the lifting protocols. While these measures remain important, they often come after the damage is done.  

This reactive mindset, while common, misses the opportunity to prevent incidents altogether. We’ll dive into why a forward-thinking strategy not only improves safety for employees, but also delivers measurable cost savings for organizations. 

Prevention is the Backbone of Occupational Health 

Manufacturing leaders know that prevention is one of the most essential elements of workplace safety, and the most effective occupational health strategies take this a step further by embedding prevention into every aspect of health and safety operations. Identifying and mitigating risks early on stops minor discomforts from turning into more serious injuries, helps organizations save on long-term costs associated with injuries and downtime, creates a safer, more productive workforce. 

A Total Worker Health® Approach 

Let’s revisit our example from earlier. During an ergonomic assessment, a trend of employees using potentially unsafe lifting form is noticed. Instead of waiting for an injury to happen, the organization takes proactive action by going beyond just adjusting the lifting protocols. They make ergonomic improvements, redesign workstations, introduce lifting aids, and provide access to resources like work conditioning, job-matching, and primary care for personal health conditions that could impact safety. These adjustments can make a significant reduction in injuries, improve morale, and increase productivity. But more importantly, workers completely avoid the strain on their families and personal lives that an injury could potentially cause. 

This example highlights the importance of a Total Worker Health® approach to occupational health. It’s not only about avoiding an OSHA fine for an on-the-job injury; it’s about considering the impact that the workplace has on an employee’s wellbeing and health. Providing health screenings and partnering with the safety teams allow providers to address immediate concerns while also considering long-term health outcomes. By prioritizing prevention and holistic care for individuals, organizations reduce both their healthcare costs and the impact of injuries on productivity, benefiting the company as a whole. 

Building a Culture of Health and Safety 

True transformation occurs when prevention, health, and safety become a part of an organization’s core focus. For manufacturers, this means creating a culture where prevention is valued and everyone is bought in, from leadership to employees working on the frontline. 

Managers Leading the Charge 

Creating a culture of health and safety in manufacturing from a leadership perspective is accomplished through a mindset of continuous improvement and leading by example. Imagine a floor manager who notices an uptick in injuries related to repetitive tasks. In many instances, these injuries may be shrugged off and addressed on a case-by-case basis. Instead, occupational health providers identify trends in injuries and have standing meetings to discuss cases and trends with leadership.  A plan to establish a comprehensive review is initiated with the expertise of ergonomic experts and changing the way work is performed so that it is safer. By showing a proactive approach, the manager not only addresses further injuries, but also builds trust among employees.  

Additionally, setting up an incentive program with safety milestones for the team can be an effective measure. Encouraging early reporting of injuries is key.  A “zero injuries in 2025” approach has been shown to discourage reporting.  Recognizing and rewarding team members for identifying hazards and reporting them further embeds safety as a shared value throughout the organization. 

Employees Taking Ownership 

By taking a Total Worker Health® approach and empowering employees to proactively maintain their own health and safety in the workplace, programs are more effective. Education on simple measures such as stretching and ensuring the protective gear is being worn properly are important but consider taking the next step. Teaching workers to be aware of early warning signs like joint pain and muscle fatigue, encouraging reporting, and providing the resources to seek early intervention prevents these small issues from turning into bigger, more complicated problems.  

Beyond injury prevention, creating a healthier workforce leads to reduced rates of presenteeism and employee attrition. When employees are empowered to take an active role in their wellbeing, they not only reduce their risk of injury but also improve energy levels, focus, and job satisfaction. This culture of accountability from employees, paired with preventive primary care, occupational medicine, and consistent buy-in from management, benefits everyone. 

The Path Forward 

Implementing these processes and changing the overall approach to health and safety for an entire organization may seem like a daunting task, but it can be started by diligently examining the current measures in place. This includes performing a gap assessment of your current injury trends and return-to-work programs to identify opportunities.  

As part of a Total Worker Health® strategy, tools like the NIOSH Worker Well-Being Questionnaire (WellBQ) can provide valuable insights to measure worker wellbeing and potential underuse of existing resources. Reviewing current claims data and incentivizing biometric screenings can provide insights needed to identify potential trends within your population that can be addressed proactively.  

By investing in these proactive approaches to health and safety, manufacturing leaders not only protect their workforce but also set the standard for operational excellence and industry innovation, ensuring long-term success in a competitive landscape. To learn how Premise Health has partnered with manufacturers and see real-world examples of this approach driving significant cost savings, download our strategic guide for auto and original equipment manufacturers. 

Source: National Institute for Occupational Safety and Health, Total Worker Health® is a registered trademark of the U.S. Department of Health and Human Services