Manufacturing safety: practical safe work practices

Safe work practices in manufacturing are the procedures that control the hazards of making things: moving machinery, hazardous chemicals, manual handling, electricity and fire. Under the WHS laws, the business is responsible for identifying those hazards and controlling them, and for consulting the people who do the work. The practices below work when they are written for your site, taught to your workers and checked regularly.

Every plant is different. A press shop, a food line and a chemical blending area have different risks, so the practices need to match the equipment, the materials and the way your crew actually works.

What are the main hazards in manufacturing?

Most serious injuries in manufacturing come from a small set of hazards:

• Moving machinery. Pinch points, rotating parts, cutting blades and flying debris can cause cuts, crush injuries and amputations.
• Manual handling. Lifting, pushing, pulling and repetitive work on lines cause back, shoulder and joint injuries.
• Slips, trips and falls. Wet floors, cables, offcuts and work at height from ladders or platforms are common causes.
• Chemicals and dust. Solvents, adhesives, cleaning agents and fumes can burn, irritate or damage health over time. Older buildings can still contain asbestos or silica dust.
• Electricity. Live wires, damaged leads and faulty equipment cause shocks and burns.
• Fire and explosion. Combustible raw materials, welding and faulty equipment can start fires.
• Noise. Loud plant causes permanent hearing loss if workers aren't protected.

Safe work practices that work

1. Start with a risk assessment

A risk assessment finds the hazards in each task, before you decide what controls to use. Look at equipment, methods and materials, and include contractors and visitors. Involve the workers who do the job, because they know where the real risks are. Review the assessment when equipment, methods or staff change.

Priority areas for most plants include machine guarding and lockout, chemical handling, lifting and manual tasks, emergency response, and hazardous waste. Run safety audits to check that the controls are working.

2. Guard and maintain machinery

Saws, presses, drills and conveyors need physical guards, interlocks where appropriate, and clear signage. Set up a maintenance schedule and keep records of inspections and repairs, because those records are the evidence you'll need after an incident. Only authorised people should have access to dangerous machinery, and a lockout/tagout procedure should control energy during maintenance. Our guide on machine guarding covers the detail.

3. Manage chemicals

Keep an SDS for every hazardous product, and make sure workers can find it. Store chemicals by compatibility, with spill containment and ventilation. Label containers, provide spill kits, and train staff on how to clean up a spill. Review the chemical register when a product changes. The SDS guide explains what to look for in each section.

4. Reduce manual handling and repetitive work

Set up workstations so people don't have to reach, twist or bend for long periods. Use adjustable benches, lifting aids and hoists for heavy loads. Rotate tasks on repetitive lines and build in breaks. Report early symptoms, such as sore wrists or backs, so they are treated before they become injuries. The manual handling guide covers lifting technique in more detail.

5. Train and supervise

Workers need training before they operate any machine or handle any chemical, and refresher training after changes. Cover how to use the equipment, what its safety features do, how to report a fault, and what to do in an emergency. Supervisors should check that the procedures are followed, and toolbox talks are a practical way to keep the messages current.

6. Use PPE as the last line of defence

PPE is needed for many manufacturing tasks: safety glasses or goggles, hearing protection, gloves matched to the task, and safety footwear. PPE only works when it fits, is in good condition and is worn. Explain when each item is needed, and store it properly. Don't rely on PPE alone to control a hazard that could be removed or guarded.

7. Control fire and electrical hazards

Identify where fire could start, such as welding areas, chemical stores and dust build-up. Install smoke alarms, put extinguishers close to likely sources and make sure staff know the evacuation routes. For electrical work, isolate equipment before work begins, and only let qualified people carry out repairs on live or fixed installations.

8. Plan for emergencies

Emergencies can include fire, a chemical spill, a serious injury or a severe weather event. Your emergency response plan should cover evacuation routes and assembly points, emergency contacts, first aid supplies, a clear chain of command and how incidents are reported. Practise it with drills, and update it after each one.

9. Consult your workers

Workers see the hazards every day, so the duty to consult them is a practical tool, not just a formality. Involve them in risk assessments, in changes to equipment, and in the review of procedures. Ask them what would make the job safer. Section 47 of the WHS Act sets out the duty to consult workers.

10. Review your performance

Track injuries, near misses and hazard reports, and inspect the plant regularly. Look for patterns, such as the same machine or task causing problems. Act on what you find, record the actions and check that they worked.

What are a manufacturer's duties under the WHS laws?

A manufacturer is a person conducting a business or undertaking (PCBU), so the primary duty of care in section 19 of the WHS Act applies. In practice, that means:

• identify hazards and put controls in place that remove or minimise the risks;
• make sure products you make or supply are safe when used as intended, and give clear instructions and warnings;
• consult the workers who carry out the work;
• cooperate with other businesses that share the workplace, such as contractors and suppliers.

The duties can't be handed to a contractor or a document. If an incident happens, the regulator will look at what you did to identify and control the hazard.

The international standard ISO 45001:2018 sets out a framework for an occupational health and safety management system. It is a useful reference if you want to build one.

Documents that support safe work

A set of written documents turns these practices into routine. Most manufacturers keep:

• a risk management plan and a register of risks;
• a safety management plan for the site;
• SOPs for each high-risk machine and task;
• a hazardous chemicals and SDS register;
• a plant register with inspection and maintenance records;
• training and induction records for every worker;
• an emergency response plan;
• incident and hazard report forms.

Our plant safety management plan and chemical SDS register are a starting point, and a machine guarding management plan pulls the guarding records together.

Common questions

Does a manufacturing task need a SWMS? Only if it is high-risk construction work. Most manufacturing tasks need a risk assessment and a clear SOP instead.

How often should machines be inspected? Follow the manufacturer's instructions and the findings of your risk assessment. Keep records of each inspection and repair.

Who is responsible for contractors on site? Your PCBU duties still apply to work you control, and you must cooperate with other businesses on site. Keep a register of contractors and check their induction and training.

What records do we need to keep? There's no single list, but you should be able to show what hazards you identified, what controls you put in place, who was trained, and what you did after an incident.

This is general information, not legal advice. Check the current law with your WHS regulator.