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How can you use MES data analysis to improve worker safety in manufacturing?

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Worker safety is a top priority for any manufacturing company. Not only does it protect the well-being of your employees, but it also reduces costs, increases productivity, and enhances your reputation. However, ensuring a safe working environment can be challenging, especially in complex and dynamic processes. That's why you need to leverage the power of MES data analysis to identify and mitigate safety risks, improve compliance, and foster a culture of safety.

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Ripal Gohel

Wind Energy R & D | Automotive | Manufacturing | Operation Excellence | Six Sigma Green Belt
Dr Prabal Bandyopadhyay

Sustainability Leader and Founding Member of "Mentors for Resourceful Collaboration (MRC) - an ESG Company with special…
Salar Mohajerani

Process Engineering Manager | Mechanical & Piping Engineering SME @ Henkel | Lean 6σ

1 What is MES data analysis?

MES stands for manufacturing execution system, a software solution that collects, monitors, and controls real-time data from your shop floor. It tracks and manages various aspects of your production, such as materials, equipment, orders, quality, and performance. MES data analysis is the process of extracting, transforming, and visualizing the data generated by your MES to gain insights and make informed decisions. It can help you optimize your operations, reduce waste, enhance quality, and increase efficiency.

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Dr Prabal Bandyopadhyay

Sustainability Leader and Founding Member of "Mentors for Resourceful Collaboration (MRC) - an ESG Company with special focus on Safety Management and Environment Protection. Ex-Hoechst, Bayer CropScience, Lafarge/Holcim
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I personally feel, we have to be much more agile in utilizing MES data proactively in improving safety at workplace. Increased reliability of a process / machine increases overall safety factor. But our focus always remain in the consequence management rather than analyzing the context proactively. Context control will give you the conscious competency to avoid an undesired event. MES data is the key in that process. Retrospective analysis of data, post consequence are becoming very expensive.

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2 How can MES data analysis improve worker safety?

One of the main benefits of MES data analysis is that it can help you identify and prevent safety hazards before they cause accidents, injuries, or fatalities. By analyzing the data from your machines, sensors, cameras, and other devices, you can detect anomalies, malfunctions, errors, or deviations that may indicate potential dangers. For example, you can monitor the temperature, pressure, vibration, or noise levels of your equipment and set alerts or triggers to notify you of any abnormal conditions. You can also use MES data analysis to track the location, movement, and status of your workers and ensure they are following the safety protocols and wearing the appropriate protective gear.

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Salar Mohajerani

Process Engineering Manager | Mechanical & Piping Engineering SME @ Henkel | Lean 6σ
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From my perspective, there is no doubt that proactive approach is much better vs. reactive approach especially in safety related topics So I think MES data such as vibration and/or noise level in different step of process can provide a better and more accurate insight for the contact level for the respective risk assessment and accordingly could help to define more precise countermeasures for the related risks Also I imagine tracing of the location of each individual could be really help full especially in emergency situations like earthquake Although checking of local regulations in such a scenario is vital Because tracking of locations of operators could be forbidden in some locations and/or based on some regulations

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3 How can MES data analysis improve safety compliance?

Another benefit of MES data analysis is that it can help you comply with the safety regulations and standards of your industry, customers, or authorities. By collecting and storing the data from your production processes, you can create and maintain accurate and reliable records of your safety performance, incidents, audits, inspections, and corrective actions. You can also use MES data analysis to generate and share reports, dashboards, or charts that demonstrate your compliance level and show your progress and improvement. Moreover, you can use MES data analysis to automate some of the safety tasks, such as scheduling maintenance, updating documentation, or sending notifications.

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4 How can MES data analysis foster a culture of safety?

A third benefit of MES data analysis is that it can help you foster a culture of safety in your organization. By using the data and insights from your MES, you can communicate and educate your workers about the importance and value of safety. You can also use MES data analysis to engage and empower your workers to participate in safety initiatives, such as providing feedback, reporting issues, suggesting solutions, or recognizing achievements. Furthermore, you can use MES data analysis to measure and evaluate your safety performance, identify gaps and opportunities, and implement continuous improvement actions.

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Ripal Gohel

Wind Energy R & D | Automotive | Manufacturing | Operation Excellence | Six Sigma Green Belt
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MES being an analysis is also a visualization on a larger scale. i.e. MES Screens on Shop floor. To create a safety culture, communication of goals towards safety is very important. That can be done through MES. For a healthy competition in safety adherence, we can have area/function wise safety performance on MES. That can work in both ways, the top performer gets appreciated and others get motivation to perform. Safety performance will always improve when it's seen and known by everyone. That can be done through MES.

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5 What are some best practices for MES data analysis?

In order to maximize the benefits of MES data analysis for worker safety, it is important to follow some best practices. These include defining safety goals and metrics, such as injury rate, near-miss rate, or safety climate score; integrating data sources to create a comprehensive view of the safety situation and performance; using the appropriate tools and techniques for MES data analysis; and acting on insights to prioritize and address safety issues or reward and motivate safety performance. Ensuring that your MES data is consistent, complete, and compatible with other data sources is also key. With these steps in place, you can gain valuable insights into your worker safety and create practical solutions to improve it.

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6 How can you get started with MES data analysis?

If you want to use MES data analysis to improve worker safety in manufacturing, you need to have a solid MES solution that can capture, process, and deliver the data you need. You also need to have a skilled and dedicated team that can analyze, interpret, and apply the data to your safety goals and strategies. Moreover, you need to have a supportive and collaborative culture that values and promotes safety as a core value and a competitive advantage.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Jason Premo

Acclaim Aerospace ?? Swiss Lathe Ultra Precision Machining ?? Aviation ?? Space??Defense ?? Pew Pews ?? Medical ?? Electronics ?? Chief Engineer & Machinist ?? STEM Ed Advocate ?? GA Tech Yellow Jacket
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Unfortunately too often MES data is only accessible by management or perhaps given to a team to analyze when there is a problem. Instead, consider empowering your manufacturing teams to determine how to make the data more accessible and meaningful, such as custom reports with filters they can analyze in different ways or even better real time data dashboards that incorporate meaningful measures and ability to drill down with analysis tools. Many MES systems incorporate or allow purchase of additional modules with these capabilities but there are also many 3rd party tools that can easily tap into database and bring data to life and make it actionable.

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Salar Mohajerani

Process Engineering Manager | Mechanical & Piping Engineering SME @ Henkel | Lean 6σ
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Despite all clear advantages of the MES I believe chance of value creation will much more higher if an organization go from "demand to supply" rather than "trend to supply" Accordingly one of the potential issues is following a trend with out a proper attention to real and/or prority requirements of the organization In such a case after an investment in MES with some general assumptions, unfirtunatly the potential destination could be facing with this vital but late question that: How can value be created from this system? So that would be great if each and every organization could ask and deep dive on this question before decision making and investment

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How can you use MES data analysis to improve worker safety in manufacturing?

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1 What is MES data analysis?

2 How can MES data analysis improve worker safety?

3 How can MES data analysis improve safety compliance?

4 How can MES data analysis foster a culture of safety?

5 What are some best practices for MES data analysis?

6 How can you get started with MES data analysis?

7 Here’s what else to consider

Manufacturing

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How can you use MES data analysis to improve worker safety in manufacturing?

1

2

3

4

5

6

7

1 What is MES data analysis?

2 How can MES data analysis improve worker safety?

3 How can MES data analysis improve safety compliance?

4 How can MES data analysis foster a culture of safety?

5 What are some best practices for MES data analysis?

6 How can you get started with MES data analysis?

7 Here’s what else to consider

Manufacturing

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