In the UK, 2.7 million people work in manufacturing (as of the final quarter of 2024). This workforce produce a wide range of goods including food & drink, electronics, plastics, machinery, transport and pharmaceuticals. Lone workers in the manufacturing sector are more vulnerable because they work without close supervision, delaying assistance in the event of an accident or emergency. Identifying this, as well as the risks they face and how to mitigate them is therefore paramount to their safety and wellbeing.
Risks when working alone in manufacturing
The main risks to those working alone in a manufacturing role are:
- Use of dangerous equipment and/or machinery
- Slips, trips or falls (this may involve working from a height)
- Carrying heavy items (manual handling)
- Noisy and/or dusty environments
- Exposure to hazardous chemicals or substances
- Shift working, including night shifts
- Security threats from intruders or vandals
- Stress and anxiety
Whilst these are hazards faced by all those working in manufacturing, the risks are even higher for those working alone or in an area that cannot be seen by colleagues or managers. This is because it is difficult for a lone worker to notify someone of an incident without anyone close by, or is impossible if they are unconscious. Manufacturing sites are often extensive, loud and have areas of low visibility so even if there are lots of people on-site an incident could easily be missed.
How to mitigate the risks of lone working in manufacturing
- Conduct a lone worker risk assessment - this should identify the risks associated with your lone workers and then assess these risks to identify the magnitude of the hazards that are posed and the steps required to protect lone working staff from them.
- Devise a specific lone working policy - a lone worker policy provides guidance for employers and employees on lone working and clarifies roles, responsibilities and procedures. It also includes Health & Safety advice, information on how to report safety concerns, and details of how to respond in an emergency.
- Provide comprehensive training - this should include training on how to operate machinery & equipment correctly and safely, manual handling training, and any training around exposure to hazardous materials, where applicable.
- Ensure the correct PPE is worn by your employees - wearing the correct PPE is vital for the safety of your workers. The type of PPE they need will vary depending on their job role, however it is critical that they understand this is essential for their safety and to avoid serious injury.
- Make sure your manufacturing site is secure - this should help to minimise the likelihood of intruders or vandals being able to access your site and enter your buildings. There are a number of ways you can do this such as; installing CCTV, employing dedicated security staff and ensuring entrances to buildings are secure and only easily accessible to staff.
- Diarise regular check-ins or contact with your lone workers to ensure workplace well-being. This helps to identify and address problems such as isolation or stress much more quickly.
- Implement a lone worker solution - lone worker apps and devices are specifically designed to keep lone workers safe and provide them with a means of communication in the event of an accident or emergency. They not only provide this critical assistance but they also improve response times and give peace of mind to both managers and lone workers.
Whilst you may have lots of people working at the same time in your manufacturing facility, it's important to recognise if you have staff members who work alone or are often out of sight. To adequately protect them you need to ensure that you have robust systems and policies in place. By conducting thorough risk assessments, implementing comprehensive training programs, and utilising technology like lone worker solutions to name a few, you can significantly reduce the risks associated with lone working in your workplace. Prioritising the safety and well-being of your lone workers not only helps prevent accidents & emergencies but also fosters a more secure and supportive work environment.