How do you keep your plant operators safe and comfortable?

I have to say, everyone has a voice when it comes to safety. Example. 1 day I noticed a person working in an area where safety gloves are required. I approached to person and said. " Hey my friend you know how much I care, I noticed your not wearing the proper safety gloves. Do you need a pair? He explained he was only be a minute working in the area. I calmly said that 1 minutes could go bad and change your life forever and I don't want to explain to family why you went to the hospital and now are physically different then the way you came to work today. His response was awesome, thank you for looking after me. I appreciate that you care Niel. I responded back your welcome. . I approach safety as again everyone has a voice.

The maintenance and development of safe practices is crucial to the maintenance of a safe workplace. Your post just screemed one question at me, who trains your trainers in the safe application of an employers procedures. Marvellous words but how do you achieve successful outcomes. ??

Establish re-training schedules with updates that address current trends and opportunities identified during operations. Information points from incident records, audits, and inspections can be used as inputs. Typical retraining cycles range from 2-3 years.

Refresher training and tracking their validity are crucial in a high risk work environment. Many times I notice people having training that are done a while ago and are still considered as 'trained'...unless a training expiry and retraining frequency is included into the training plan I believe a training program is not fully effective and efficient...

Having a Baseline Ergonomic (MSD) Risk Assessment cycle into your risk assessment program will help to look more closely into ergonomic related hazards and implement effective control measures.

This should be considered in the design phase. Things like properly locating valves and other equipment that require frequent operation and maintenance for easy access. Designing facilities with proper head rooms, ventilation, and lighting is also critical.

Culture of trust & ownership is the key. Once, an operator spoke to me in an unexpected manner on a call. As per SOP, I could have confronted him to make him realize, but why would I? I knew he was working a lot (this is a story from COVID-19 times , when it was at peak). Today, that operator is my top performer and my best friend, like many others. EMPATHY is important; understanding the situation is crucial. If your culture is not good, no matter how big your company is or how prominent the brand is, FAILURE is waiting for you, sooner or later.

Promote a learn and improve mindset to ensure continuous improvement in all aspects of the operation and maintain the integrity of dedicated systems.

I agree with the comments and suggestions but the word " communication" seems too broad of a suggestion. Specifically I suggest managers and supervisors making constant and daily walks to talk and listening to the operators and mechanics who operate and constantly repair -adjust the machinery and equipment. They know and"listen" to the process equipment day in and day out. They can detect and "feel" small variances from the normal operations of the equipment before a major issue becomes a bigger one. They,better than anyone else,are the ones who can help on the uptime if only we establish constant communication with the frontline and gatekeepers who know the equipment better than anyone else.

We regularly conduct Work Environment Measurement done by a certified Industrial Hygienist. Assesssed hazards were then prioritized and controlled appropriately.

Plant operators, admin employees, and other emoloyees are involved in our HIRAC Process. Our RAM is reviewed at least twice a year and the contributions of each department's members are very helpful, that's why we don't miss any process and hazards are identified and controlled.

I am working in chemical manufacturing plants for 18 years, and I found that the most important reason for workplace accidents is the negligence of following the safety instructions in performing the required jobs due to improper training and lack of supervision.

It's important to provide appropriate training, ensuring that the plant environment is well-maintained and free from hazards. Regular breaks and offering ergonomic workstations can contribute to the operator's comfort. Frequent safety inspections, hazard assessments, and communication about safety procedures are also essential for maintaining a safe and comfortable work.

Promote a psychological safe work place where plant operators can bring their authentic selves to work and can provide honest undiluted feedback/opinions/observations without fear of any negative consequences. Design systems that are resilient, to reduce the likelihood and severity of error likely situations. Improve the interaction between operators with the systems, equipment, processes, procedures, and culture that they work with by removing error traps.