3 ways to implement smarter safety for smarter manufacturing

Employees are the first line of defence. They are the eyes and hands on the ground. Hence, employees need to be empowered to play their part for safety. This means creating an environment in which they are comfortable to act positively in the name of safety. For this to be effective, organisations can cultivate a blame-free environment. Workers must be empowered to flag hazards without fear of reprisals. A proactive mindset can help catch near misses and fix gaps in safety before an incident occurs.

For instance, Singapore Aero Engine Services Private Limited (SAESL), a Rolls-Royce subsidiary and Trent Centre of Excellence, reduced its accident rate by 65 percent over the past three years. Its near-miss reporting regime introduced in 2012 allows employees to flag safety compromises, even going as far as to allow them to stop work if they spot a safety issue. “Safety has no budget limit. Our goal is to have zero harm and injuries in the spirit of Rolls-Royce’s ‘Zero Harm’ initiative,” Bill Wozniak, CEO, SAESL, explained.

In the main facilities of Rolls-Royce such as the Seletar Assembly and Test Unit (SATU) and Fan Blade Singapore facility, management takes a global-to-local approach.

Safety scenarios and best practices from the company’s facilities across the world are shared among management, who then apply the knowledge to existing processes and shop-floor employees. Employees are also encouraged to share their thoughts and feedback on these practices and how existing methodologies can be refined for more safety.

“This top-down and bottom-up approach creates a dynamic dialogue throughout all layers of the organisation, not just in the region but across the world. By tapping into our global network of talent, it helps us identify potential gaps and implement solutions faster,” said Ben Khoo, Manufacturing Manager, SATU, Rolls-Royce.

The evolution of smart manufacturing will lead to smarter ways of working that will both improve productivity and ensure workplace safety. Automation and robotics will reduce human errors and by minimising human involvement, staff are freed up to do more value-added strategic tasks that are less dangerous. Meanwhile, AI and data analytics can discover new efficiencies in existing processes and help design new methodologies that are safer and more productive.

For instance, the process of fan blade manufacturing is extremely hazardous. The usage of certain chemicals such as hydrochloric acid can cause damage to skin and bone if not handled correctly. Workers are also potentially exposed to high-heat situations for extended periods of time and must wear protective gear. Meanwhile, the strenuous work of polishing the blade can cause employee’s muscles to wear and tear due to overuse. Extensive hand-arm vibration is a huge concern when employees are exposed to prolonged use of high-vibrating equipment. Such processes can be helped with automation and robotics. Robotic arms can replace mechanical ones when it comes to using chemicals. Meanwhile, machines can be deployed to work in high-temperature environments to reduce human exposure and chances of accidents.

While manufacturing methodologies and processes are improving tremendously, processes and controls must still be designed to complement safety standards.

“Technologies get smarter, but there will always be an element of uncertainty due to human error or design flaw. Hence, we cannot afford to be careless even when new and better capabilities are being rolled out,” Ben said. In SATU, programmes such as Life Saving Rules are implemented to prevent accidents. Employees are constantly reminded to wear the appropriate equipment, use approved lifting methods and obeying speed limits when it comes to driving factory vehicles. The programme also accounts for lifestyle factors, forbidding employees to work under the influence of alcohol or using their phones while handling equipment.

The Rolls-Royce Machine Safety Programme also calls for features such as easy access to shutoff switches, machine guards over moving parts, and braking systems for spindles. Ceramic safety cutters are also used in place of metal blades and staff must undergo Hands Safety Awareness training.