Health and safety in an era of smart manufacturing

“Whenever we have a conversation about industrial safety, there seems to be an implicit misunderstanding that it gets in the way of productivity. However, the truth is that safety practices can actually help better understand and improve the performance of operations,” Akhilesh explained.

Smart manufacturing is rewriting the production and safety playbooks. Companies are already using greater connectivity and data to create smarter, higher-performing production. However, such capabilities don’t just benefit production operations alone. By applying them to industrial safety efforts, organisations can improve productivity, minimise downtime and boost safety performances.

By implementing safety devices in operations and giving workers deeper insights into those devices, such technologies can boost productivity, identify and resolve common machine-stoppage problems - and even predict production issues before they happen. Some potential applications include:

• Smart safety devices that access safety data that until now wasn’t being generated or couldn’t be extracted from systems can provide never-before-seen insights
• Safety data collected by smart safety devices can create a “trail of bread crumbs” that point to larger issues impacting production
• Safety device data can also help identify discrepancies between policies and operating procedures that affect uptime

At Rolls-Royce facilities, new Industry 4.0 technologies that aid safety are already being implemented. 3D visualisation software technology is allowing employees to become more aware of their workplace surroundings and its related dangers. Machine learning technology is helping in PPE (personal protective equipment) compliance monitoring. Meanwhile, robotic arms are being used to replace manpower for dangerous tasks such as furnace operations.

Culture is also an important part of the equation. Hence, creating an environment where everyone can be at their best is a crucial part of safety strategy.

“To help achieve this at Rolls-Royce, we have our Zero Harm initiative. We need to get to a place where ‘Zero Harm’ is so firmly embedded in our DNA that whatever we are planning or doing in our business – whether it’s eliminating health, safety and environmental risks - will simply be part of how we do things here. It’s not about the numbers. It’s about a mind-set that poses a constant call to action – ‘What can I do to further reduce or eliminate any adverse effects arising from the work we do?’

The Zero Harm programme is a five-part model that serves as a guide for employees to develop a proactive mindset and spirit when it comes to safety. In a landscape where technologies, regulations and processes are changing so rapidly, this model helps employees realise that taking a reactive stance is no longer enough. Moving towards proactive and high reliability positions will not only ensure better work practices today, but also enable improved safety tomorrow. To help employees, Rolls-Royce is providing one comprehensive source of information where they can access a range of guidance and tools across the business.

With more collaboration going on, organisations also have to take into account the safety practices of their partners. Regardless of size, employers should be aware of the significant importance of health and safety and have robust processes in place to protect employees, contractors and the public.

“It can be difficult to gain and maintain visibility over activities and outstanding actions across multiple sites when working with many contractors. Hence, controls need to be put in place to ensure only approved contractors have site access and contractor insurance certificates are up to date. We also ensure that qualified contractors only undertake work they are trained for and appropriate risk-assessments have been completed and signed off before work begins,” Akhilesh said. 

Rolls-Royce has implemented a robust “Control of Contractors” standard to manage health and safety risks related to its contractors. It covers four key areas: pre-job planning, pre-qualification, orientation and feedback. All partners of Rolls-Royce are part of the company’s management system and responsible for delivering expected performance while working at Rolls-Royce’s sites or facilities. They have access to common tools, trainings and practices which enable them to work safely and effectively.

As employees transition into more value-added jobs in smart manufacturing, it becomes increasingly important for them to have the focus and the supportive environment to help reach their full career potential and unlock better performance.

“While smart manufacturing has the potential to make people’s lives better, we must not take their personal struggles and emotional well-being for granted. It is still important for organisations to offer not only offer more holistic ways of working and living, but also be mindful of delivering that human touch of support unavailable from technology,” Akhilesh said.

Rolls-Royce has rolled out initiatives and trainings to help employees manage their stress effectively. The company has an ongoing employee support programme that provides a platform for them to raise their issues and concerns. Fun activities such as yoga and Zumba are also organised to provide a vibrant working environment and raise employee morale. The company also dedicates a week to raise awareness for mental health and tracks employee well-being with benchmarks such as employee opinion surveys.

Amid the rapid evolution of smart manufacturing, people will remain the most important asset of any company. Ensuring their health and safety will improve company morale, and even productivity and efficiency. Organisations can turn safety into a competitive advantage with technology. Through employee education and partner controls, they can also deliver consistent safety experiences within the organisation and in the wider ecosystem. Health and safety also doesn’t stop just there. It’s also important to offer holistic well-being with care for mental health. By transforming workplaces holistically, organisations can build a better environment to adopt and implement Industry 4.0 effectively and responsibly.  

References:

¹ International Labour Organisation, Relevant SDG Targets related to Health and Safety at the Workplace.

² International Labour Organisation, World Day for Safety and Health at Work 2019.