Justifying Safety Through Quality Improvements

An Unsafe Workplace Is Also An Unproductive One

We've all heard about the return on investment (ROI) dilemma, which often results in many businesses treating safety and productivity as competing priorities. However, the reality is that an unsafe workplace is also an unproductive one. Justifying safety through quality improvements and productivity improvements can be smart business. In high-risk industries such as manufacturing, construction, and logistics, workplace safety directly impacts efficiency, quality, and ultimately profitability. Throughout history, many safety innovations have originated from efforts to improve productivity. Understanding this connection can help companies justify investments in safety improvements by framing them as essential to operational excellence.

The Evolution of Justifying Safety Through Productivity Initiatives

Most major safety innovations in heavy industry have stemmed from attempts to increase productivity rather than from purely regulatory or humanitarian efforts. For instance, early factory automation reduced the need for manual labor in dangerous conditions. Ergonomic workstation designs were introduced to reduce worker fatigue, which in turn improved output consistency. Conveyor belts, robotics, and lean manufacturing techniques were all originally meant to drive efficiency but ended up being instrumental in reducing workplace injuries.

One notable example is the steel industry’s transition from open-hearth furnaces to basic oxygen furnaces. This shift dramatically improved production speed while simultaneously reducing the exposure of workers to extreme heat and toxic fumes. Similarly, the adoption of predictive maintenance, initially intended to minimize equipment downtime, also helped prevent catastrophic failures that could lead to worker injuries.

According to a study by the Occupational Safety and Health Administration (OSHA), workplaces that implement effective safety and health programs can reduce injury and illness costs by 20 to 40 percent. Another report by the National Safety Council found that preventing workplace injuries can yield a 6:1 return on investment.

Justifying Safety Through Quality Improvements

A common challenge businesses face is justifying the return on investment (ROI) of safety technology. Safety improvements often require significant upfront costs, and businesses may struggle to quantify their financial benefits. However, when these investments also solve productivity or quality control issues, the justification becomes clearer. Unions and workers may fear that these improvements may remove workers’ jobs. But it’s not about automating and eliminating jobs. Instead, we’re able to make existing workers more efficient and productive while improving quality and safety.

For example, when a company has employees doing work in confined spaces, they must follow regulations for monitoring them in specific ways during that work. One of our clients was previously monitoring workers via video feeds. One safety expert was only able to monitor 16 confined space entrances at a time, so there would sometimes be occasions where work in a new confined space would need to be put on hold until the safety expert had the capacity and was able to monitor a new entrance. But after we added the WorkVis.io Artificial Intelligence (AI) Solution for Confined Spaces, that same safety expert was suddenly able to safely monitor four times the number of cameras, or 64 confined space entrances. Not only is it more productive, but it makes it possible to monitor new spaces that weren’t being monitored before, improving safety, productivity, and morale. We make it possible for workers to level up and do more.

Consider a manufacturing company that was hesitant to invest in an automated machine guarding system due to cost concerns. The company experienced near-miss incidents and minor injuries, but executives found it difficult to justify the expense based solely on reducing injury rates. However, after experiencing an increase in product defects due to worker fatigue and inconsistent machine operation, they revisited the investment. The automated system not only protected workers from hazardous moving parts but also improved product consistency and reduced rework. By framing the investment as a quality and efficiency improvement rather than just a safety measure, leadership approved the funding. Everyone wins by justifying safety through quality improvements.

Balancing Safety and Productivity: Trade-Offs and Misconceptions

One of the biggest misconceptions in industrial operations is that productivity and safety are inherently at odds. While it’s true that safety measures can sometimes slow down processes in the short term, they almost always result in higher long-term efficiency. Frequent injuries lead to absenteeism, workers operating in fear, and high turnover, which leads to loss of expertise and the need to train new workers, factors that reduce output. In contrast, a well-designed safety program fosters a culture of reliability and confidence, leading to smoother operations.

That said, there are trade-offs. Overly rigid safety procedures can create bottlenecks, and companies must find a balance. For example, requiring extensive lockout/tagout (LOTO) procedures for every minor adjustment in a production line might slow operations unnecessarily. In such cases, solutions like interlocked guarding and smart sensors can maintain safety while allowing for efficiency.

Conclusion: Safety and Productivity Go Hand-in-Hand

An unsafe workplace is, by definition, an unproductive workplace. Businesses that prioritize safety will ultimately see improvements in efficiency, quality, and worker retention. The history of industrial innovation shows that many of the most significant safety improvements originated from efforts to boost productivity. By leveraging automation, AI, and data-driven insights, companies can eliminate the false dichotomy between safety and efficiency, ensuring that workers stay protected while businesses thrive. The key is to view safety not as a compliance obligation but as a critical driver of long-term success. And you conquer the ROI dilemma by justifying safety through quality improvements and productivity investments.

Sources

Occupational Safety and Health Administration (OSHA): Business Case for Safety and Health https://www.osha.gov/businesscase
National Safety Council (NSC): Work to Zero https://www.nsc.org/workplace/safety-topics/work-to-zero

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