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Injury Prevention Resources for Manufacturing

The following links list tools, publications, and other resources to help prevent the most common injuries and illnesses in the manufacturing industry. These resources may not meet all the requirements for health and safety in British Columbia. Please check the Workers Compensation Act, the Occupational Health and Safety Regulation, and related materials for specific WorkSafeBC requirements.

General | Combustible Dust | Confined Spaces | Ergonomics | Lockout | Machinery & Equipment (Safeguarding) | Mobile Equipment | Personal Protective Equipment (PPE) | Hearing Protection | Slips, Trips & Falls | Young Worker

General


Manufacturing Safety (PDF 1.3 MB)
This publication was produced for employers, supervisors, workers, joint committees, and safety professionals as a guide to safety-related issues in their daily work environment. Interested stakeholders may also refer to or use the information contained in this document to assist them in carrying out their occupational health and safety roles and responsibilities.
Source: WorkSafeBC WorkSafeBC
* Available for purchase from the WorkSafeBC store.

Ladder Safety Series
This series has been developed to provide information that should help encourage safe work practices when using ladders.
Source: WorkSafeBC WorkSafeBC

Due Diligence (video)

video thumbnail Due Diligence outlines the safety responsibilities of employers, supervisors, and workers. Using clips from WorkSafeBC videos and commercials, Due Diligence vividly portrays the human cost of workplace accidents. (12 min 21 s)
Source: WorkSafeBC WorkSafeBC

Combustible Dust


Combustible Dust
Many manufacturing processes can create dust. Those dusts may pose a risk for fires or explosions. Industries that produce dust as a result of work processes, or use a fine material (dust) as a raw product, need to be aware of those risks and take appropriate steps to mitigate them. These industries include, but are not limited to: food, plastic, chemical or metal products manufacturing. Combustible dusts collect on floors or equipment, as well as on any raised horizontal surfaces such as rafters, roofs, and suspended ceilings. Combustible dusts can also be found inside ducts, crevices, dust collectors, and other equipment. In the right circumstances, the build-up of even a very small amount of dust can lead to an explosion resulting in serious injuries or even death.

In order to raise awareness about the hazards of combustible dusts, WorkSafeBC recommends that all manufacturing employers review the informative materials on the Canadian Centre for Occupational Health and Safety's (CCOHS) webpage on combustible dust. If you're an employer, this important information will assist you in identifying the combustible dusts you might have in your workplace, the conditions required for a dust explosion, and what prevention measures you can put in place to reduce the risk of a combustible dust fire or explosion.

See also Combustible wood dust tool box resources.

Confined Spaces


Multimedia

Confined Spaces: Safe yesterday, deadly today (1 of 3) (video)

video thumbnail Identify the confined spaces in your workplace as a first step in reducing their hazard. (3 min 22 s)
Source: WorkSafeBC WorkSafeBC

Confined Spaces: Test to live (2 of 3) (video)

video thumbnail Test the atmosphere before entering a confined space. It can make the difference between life and death. (3 min 38 s)
Source: WorkSafeBC WorkSafeBC

Confined Spaces: Rescue - just calling 911 doesn't cut it (3 of 3) (video)

video thumbnail Successful rescue requires proper planning, training, equipment, and practice. (3 min 04 s)
Source: WorkSafeBC WorkSafeBC

Confined spaces: deadly spaces (video)

video thumbnail This video is designed for municipal workers and illustrates the basic rules for working in confined spaces. Oxygen deficiency and other potential dangers are covered. In addition, the health effects and physical characteristics of toxic gases including carbon monoxide, hydrogen sulphide, and methane are examined. (12 min 56 s)
Source: WorkSafeBC WorkSafeBC

Precious Time - The Cody McNolty story (video)

video thumbnail

This video contains language that may be offensive to some, viewer discretion is advised.
This video documents the story of Cody McNolty, a confined space rescue that goes tragically wrong. It was created to raise awareness among employers and workers about the importance of adequate health and safety training, and safe work procedures for entering confined spaces. (9 min 35 s)

Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets

Hazards of Confined Spaces (PDF 912 KB)
This book describes the main types of hazards found in confined spaces. Confined spaces may contain hazardous atmospheres, including insufficient oxygen, toxic (poisonous) air, or an explosive atmosphere.
Source: WorkSafeBC WorkSafeBC

Also available in the following languages:

* Print copies are available for purchase from the WorkSafeBC Store

Toolbox meeting guides

Confined Spaces Toolbox Meeting Guides
Source: WorkSafeBC WorkSafeBC

Visit the confined spaces web pages for more information.

Machinery and Equipment (Safeguarding)


Multimedia

Guarding (video)

video thumbnail This video describes the types of guards available for different work situations and how their use can prevent injuries and save lives.(14 min. 46 sec.)
Source: WorkSafeBC WorkSafeBC

Too Much To Lose (video)

video thumbnail An experienced worker loses his fingers when he uses a dangerous piece of equipment without a guard. (3 min. 12 sec.)
video guide (PDF 252 KB)
Source: WorkSafeBC WorkSafeBC

Safeguarding in Food Products Manufacturing (slide show)

video thumbnail With everything there's a cost - with food production, I'm going to tell you what that cost is. (3 min. 5 sec.)
Source: WorkSafeBC WorkSafeBC

Safeguarding in Metal Products Manufacturing (slide show)

video thumbnail Every year several hundred manufacturing workers in B.C. injure their hands due to missing or inadequate safeguarding. Don't be one of them. (2 min. 30 sec.)
Source: WorkSafeBC WorkSafeBC

Guarding for Woodworking (slide show)

video thumbnail Effective point-of-operation safeguarding and safe work practices can help to prevent serious injuries when using table and panel saws. (4 min. 40 sec.)
Source: WorkSafeBC WorkSafeBC
Booklets and pamphlets

Safeguarding Machinery and Equipment: General requirements (PDF 4.6 MB) space
This manual is for everyone who owns, operates, maintains, or sells powered machinery and equipment.

  • Employers will find information to help them comply with the Occupational Health and Safety Regulation (OHSR) and Part 3 of the Workers Compensation Act. It will also help them exercise due diligence in providing a safe work environment.
  • Supervisors will find information to help them assess the risks to their workers from harmful contact with machinery and equipment.
  • Workers will gain greater awareness of the hazards associated with equipment operation and maintenance and of the safeguarding protection they have a right to expect.
Source: WorkSafeBC WorkSafeBC
* Print copies are available for purchase from the WorkSafeBC Store

For your convenience and ease of use, the chapters of this book are available as individual PDFs. Chapter 4 has been further divided into sections that highlight specific guarding requirements for specific types of equipment. These sections have separate covers so that they can be printed and used on their own.

Cover, WorkSafeBC info, title page, acknowledgements,
CCIP data, table of contents
Front matter (PDF 416 KB)
Introduction Intro (PDF 100 KB)
1. Hazard Recognition Chapter 1 (PDF 504 KB)
2. Risk Assessment Chapter 2 (PDF 120 KB)
3. Design and Selection Criteria for Safeguards Chapter 3 (PDF 2.1 MB)
4. Some Common Safeguarding Applications Chapter 4
    • Power transmission guards
Section 1 (PDF 611 KB)
    • Conveyors
Section 2 (PDF 120 KB)
    • Feed rolls
Section 3 (PDF 2.1 MB)
    • Metal-forming equipment
Section 4 (PDF 424 KB)
    • Abrasive equipment
Section 5 (PDF 629 KB)
    • Woodworking equipment
Section 6 (PDF 435 KB)
    • Robots
Section 7 (PDF 506 KB)
Appendices Appendices (PDF 552 KB)
Zip archive containing all of the above files
(requires zip utility to compress)
Zip archive (ZIP 6.4 MB)

 

Safeguarding in Manufacturing (PDF 733 KB)
(A companion guide to the Safeguarding Machinery and Equipment manual).
This guide provides information to help employers comply with the Occupational Health and Safety Regulation (OHSR) and Part 3 of the Workers Compensation Act. It will also help them exercise due diligence in providing a safe work environment.

Supervisors will find information to help them assess the risks to their workers from harmful contact with machinery and equipment. Workers will gain greater awareness of the hazards associated with equipment operation and maintenance and of the safeguarding protection they have a right to expect.
Source: WorkSafeBC WorkSafeBC
* Print copies are available for purchase from the WorkSafeBC Store

Safe Operation of Grinders (PDF 60 KB)
This placard can be posted in the workplace and outlines the proper installation and proper use of grinders.
Source: WorkSafeBC WorkSafeBC

Information sheets

Machine risk assessment survey (PDF 267 KB)
This document will help identify hazardous machine motion to which a worker may be exposed. It also contains the "hierarchy of safeguarding controls" as a reference.
Source: WorkSafeBC WorkSafeBC

Machine guarding checklist (PDF 248 KB)
This checklist can be used to analyze the machinery in your workplace. Reproduced with permission from Canadian Auto Workers Union video "Blowin' in the Wind - Machine Guarding Prevents Death."
Source: WorkSafeBC WorkSafeBC

Don't let your guard down (PDF 211 KB)
"Accidents involving unguarded machinery and equipment often result in disfiguring injuries, amputations, and death. Safeguarding is your first and best defence against these types of accidents." From WorkSafe Magazine, May/June 2006.
Source: WorkSafeBC WorkSafeBC

Hazard alert posters
  • Fatality 2009-03 Worker dies when struck by board after kickback
  • HA 08-15 Worker's hand crushed in pinch point of malfunctioning punch press
  • HA 08-07 Worker struck when cutting wheel shatters and grinder recoils
  • WS 06-07 Industrial lasers can cause serious eye injuries and severe burns
  • AA 04-06 Workers seriously injured in conveyor accidents
  • HA 04-06 Pasta machine catches sleeve, breaks hand
  • HA 04-03 Baker's arm caught in bread dough machine
Regulation and guidelines
Web resources

Machine Safety - Prevention of mechanical hazards (PDF 12 MB)
This guide describes the use of safeguarding to eliminate or reduce hazards in the manufacturing sector. Although the guide refers to standards for the province of Quebec it presents the information in a manner that will be useful for anyone that wants to learn about safeguarding methods and concepts.
Source: IRSST (Institut de recherche Robert-Sauvé en santé et en sécurité du travail)

Safeguarding of Hydraulic Power Press Brakes (PDF 4.8 MB)
The objective of this document is to inform companies about the means available for safeguarding hydraulic power press brakes, while emphasizing the two most recent solutions: the safety light curtain and the laser beam device.
Source: IRSST (Institut de recherche Robert-Sauvé en santé et en sécurité du travail)

Machine guarding eTool (HTML)
This eTool focuses on recognizing and controlling common amputation hazards associated with the operation and use of certain types of machines.
Source: OSHA (Occupational Safety and Health Administration), US

Concepts and Techniques of Machine Safeguarding
"This manual has been prepared as an aid to employers, employees, machine manufacturers, machine guard designers and fabricators, and all others with an interest in protecting workers against the hazards of moving machine parts." (1992; revised)
Source: OSHA (Occupational Safety and Health Administration), US

Ghost in the Machine: Protect Yourself from Injury (HTML)
"Safe use of machinery lands in the top 10 most frequently issued workplace inspection orders by Ontario Ministry of Labour."
Source: Workplace Safety North

Self-assessment forms for occupational health and safety (HTML)
These forms can be used by employers, supervisors, workers and or health and safety committees.
Source: IAPA (Industrial Accident Prevention Association Ontario)

OSH Answers: Powered hand tools
Information presented in question-and-answer format.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)

Preventing deaths and injuries while compacting or baling refuse material
"This Alert describes five cases of fatal injuries that resulted when workers entered, fell, or were caught and pulled into energized compacting or baling equipment."
Source: NIOSH (National Institute for Occupational Health and Safety)

Ergonomics


Multimedia

Lifting in the Workplace (video)

video thumbnail Lifting is a common task in many workplaces. This animated video illustrates the risk associated with lifting and suggests ways to reduce this risk. (1 min 29 s)
Source: WorkSafeBC WorkSafeBC

Booklets and pamphlets

Safety in Manufacturing - Ergonomics
These worksheets can be used as a guide to identify ergonomics risk factors commonly found in the manufacturing industry. They also include some recommended limits along with possible control options.

Source: WorkSafeBC WorkSafeBC

Making It Right: Preventing musculoskeletal injuries (MSIs) in manufacturing (PDF 1.3 MB)
This publication provides guidance to help employers, joint health and safety committees, and worker health and safety representatives understand the risk of MSI and make simple changes in the workplace to reduce the risks and make manufacturing tasks easier to perform.
Source: WorkSafeBC WorkSafeBC
* Print copies are available for purchase from the WorkSafeBC Store

Back Talk: an owner's manual for backs (PDF 706 KB)
An illustrated handbook that explains how the back works, provides tips for avoiding injury, and shows how to care for the back during recovery. The booklet also covers situations that can cause excessive loads and describes ways to reduce the risk of injury.
Updated: November 2011
Source: WorkSafeBC WorkSafeBC
* Print copies are available for purchase from the WorkSafeBC Store
* A free ebook version for iPad is available on iTunes

Preventing Musculoskeletal Injury (MSI): a guide for employers and joint committees (PDF 4 MB)
This book provides guidance to help employers and joint committees prevent MSI in the workplace. It discusses the MSI prevention process: consultation, education, risk identification, risk assessment, risk control, training, and evaluation. The book also includes a table of some common risk control options and a chart that can be used to investigate MSIs.
Source: WorkSafeBC WorkSafeBC
* Available for purchase from the WorkSafeBC Store.

Understanding the Risks of Musculoskeletal Injury (MSI): an educational guide for workers, on sprains, strains, and other MSIs (PDF 1.2 MB)
A guide to help workers and employers recognize the signs and symptoms of MSI and understand the potential health effects of these injuries. Helps to identify the factors that place workers at risk for MSI, such as force, repetition, work posture, and local contact stress.
Updated: December 2008
Also available in the following languages:

Source: WorkSafeBC WorkSafeBC
* Available for purchase from the WorkSafeBC Store.

Assessment tools

Lift / Lower Calculator

Lift/Lower Calculator This calculator takes into account some common risk factors and then helps you estimate whether a lift has a low, moderate, or high risk of injury.
Source: WorkSafeBC WorkSafeBC

Push/Pull/Carry Calculator

Push/Pull/Carry Calculator This calculator can be used to estimate the suggested maximum force that can be used during pushing and pulling, and the weight that can be carried.
Source: WorkSafeBC WorkSafeBC

Web resources

Lockout


Multimedia

Lockout: a guide to safe work practices (video)

video thumbnail This video provides a comprehensive overview on locks used to control energy in machines. Protect your workers from accidents caused by the inadvertent operation of control devices. (35 min 39 s)
Source: WorkSafeBC WorkSafeBC

Lock out. It takes just seconds to lose a limb. (slide show)

video thumbnail This slide show describes two accidents, each where a worker lost a limb following improper lockout. (2 min 58 s)
Source: WorkSafeBC WorkSafeBC

Lockout for woodworking (slide show)

video thumbnail De-energizing woodworking machinery when doing maintenance prevents injury. See the basic steps for locking out. (2 min 42 s)
Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets

Lockout (PDF 2.4 MB)
This booklet defines lockout, explains lockout policy and procedures, and provides guidance on compliance with Regulation requirements.
Source: WorkSafeBC WorkSafeBC
* Available in Simplified Chinese, Traditional Chinese, Korean, Punjabi, Spanish, and Vietnamese.
* Print copies are available for purchase from the WorkSafeBC Store
* A free ebook version for iPad is available on iTunes

Lockout Crew Talk
Source: WorkSafeBC WorkSafeBC

Toolbox meeting guides

Lockout Toolbox Meeting Guides
Source: WorkSafeBC WorkSafeBC

WorkSafe Bulletin

imageMake sure all moving parts have stopped completely when locking out sawmill machinery
Source: WorkSafeBC WorkSafeBC

Mobile Equipment


Multimedia

Fields of Vision: Pedestrian Safety around Forklifts (video)

video thumbnail This video, in dramatic style, puts you into the driver's seat and shows you how difficult it is for the lift truck operators to see pedestrians. The video then outlines simple ways pedestrians can help lift truck drivers see them - and avoid a serious or fatal accident. (12 min 20s)
Source: WorkSafeBC WorkSafeBC

Young worker falls from forklift (slide show)

thumbnail A young worker new to the job falls 13 feet off a forklift's platform onto a concrete floor. (4 min 41 s)
Source: WorkSafeBC WorkSafeBC

Forklift crushes worker (slide show)

thumbnail Don't rely on just the parking brake. Lower the forks before exiting the cab. (2 min 59 s)
Source: WorkSafeBC WorkSafeBC

Forklift tips over, crushing operator (slide show)

thumbnail Slide show of an accident investigation where a forklift operator died when his forklift tipped over. (1 min 52 s)
Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets

Safe Operation of Lift Trucks (PDF 86 KB)
This pamphlet describes the responsibilities lift truck operators have for the safe operation of their vehicles, as well as some of the things to avoid when working on, in, or near forklifts, platform trucks, powered small-pallet trucks, or similar powered units.
Source: WorkSafeBC WorkSafeBC

Personal Protective Equipment (PPE)


Multimedia

When are work gloves dangerous? (slide show)

slideshow thumbnail Wearing gloves can actually create a danger when working around machinery with moving parts. (2 min 45 s)
Source: WorkSafeBC WorkSafeBC

Grinders: What's the right eye protection? (slide show)

slideshow thumbnail Safety glasses or goggles alone often do not provide sufficient protection when using grinders. (2 min 10 s)
Source: WorkSafeBC WorkSafeBC

Look at Me (video)

video thumbnail A worker who does not use eye protection while operating a grinder suffers a serious eye injury. (3 min 53 s)
video guide (PDF 252 KB)
Source: WorkSafeBC WorkSafeBC

Fall Protection (video)

video thumbnail Fall Protection highlights the need for fall protection systems in the workplace. With dramatic footage of accidents and computer animation, this video outlines the steps to develop safe practices when working from heights. (11 min 42s)
Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets

An Introduction to Personal Fall Protection Equipment (PDF 545 KB)
This booklet outlines the safe use and limitations of personal fall protection equipment.
Source: WorkSafeBC WorkSafeBC
* Available in Simplified Chinese, Traditional Chinese, Korean, Punjabi, Spanish, and Vietnamese.
* Print copies are available for purchase from the WorkSafeBC Store

Breathe Safer: How to use respirators safely and start a respirator program (PDF 3.4 MB)
This manual helps explain the requirements of the Occupational Health and Safety Regulation and is a tool to help you work safely in workplaces where there are breathing hazards.
Source: WorkSafeBC WorkSafeBC
* Print copies are available for purchase from the WorkSafeBC Store
Updated: October 2011

Toolbox meeting guides

Personal Protective Equipment Toolbox Meeting Guides
Source: WorkSafeBC WorkSafeBC

Information sheets

Personal Protective Equipment (PPE) Information Sheets by Industry - Manufacturing
A series of information sheets have been developed to provide a simple, clear format to help explain how to select, use, and maintain your personal protective equipment.
Source: WorkSafeBC WorkSafeBC

Web resources

Respirator Selection
This document describes how respiratory hazards are controlled, what you should know before selecting a respirator, the different types of respirators, and how to select the right respirator.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)

Respirator Care
This document provides checklists for caring for respirators and self-contained breathing apparatus.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)

Visit the personal protective equipment (PPE) web pages for more information.

Hearing Protection


Multimedia

The Hearing Video (video)

video thumbnail This video describes the types of guards available for different work situations and how their use can prevent injuries and save lives.(14 min 46 s)
Source: WorkSafeBC WorkSafeBC

Deaf to the Danger: Packing Plant Scenario (video)

video thumbnail This video demonstrates the dangers associated with wearing earbuds on the job in a packing plant. (1 min 25 s)
Source: WorkSafeBC WorkSafeBC

Deaf to the Danger: Warehouse Scenario (video)

video thumbnail This video demonstrates the dangers associated with earbuds on the job in a warehouse. (1 min 23 s)
Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets

Hear for good: Preventing noise exposure at work (PDF 280 KB)
"Noise is one of the most pervasive problems in today's occupational environment, affecting workers in manufacturing, construction, transportation, agriculture, and the military."
Source: WorkSafeBC WorkSafeBC

Toolbox meeting guides

Hearing Loss Prevention Toolbox Meeting Guides
Source: WorkSafeBC WorkSafeBC

Web resources

A Practical Guide to Effective Hearing Conservation Programs in the Workplace
"Noise is one of the most pervasive problems in today's occupational environment, affecting workers in manufacturing, construction, transportation, agriculture, and the military."
Source: NIOSH (National Institute for Occupational Safety and Health)

Visit the hearing loss prevention web pages for more information.

Slips, Trips and Falls


Multimedia

Housekeeping in woodworking (slide show)

video thumbnail Prevent slips, trips, falls, and injuries in your woodworking shop through simple housekeeping techniques. (1 min 46 s)
Source: WorkSafeBC WorkSafeBC

Young construction worker dies from fall (slide show)

video thumbnail Falls are a leading cause of fatalities in construction. In this slide show, a young worker died when he fell from a balcony. (3 min 1 s)
Source: WorkSafeBC WorkSafeBC

Falls from ladders (video)

video thumbnail This video demonstrates the importance of providing and following proper instruction on ladder use. (2 min 0 s)
Source: WorkSafeBC WorkSafeBC

Falls through Openings (video)

video thumbnail This video demonstrates the importance of proper planning, use of guardrails, and the right fall protection equipment. (1 min 41 s)
Source: WorkSafeBC WorkSafeBC

Falls from Top Plate (video)

video thumbnail This video demonstrates the importance of proper planning, use of guardrails/work platforms, and the right fall protection equipment. (2 min 6 s)
Source: WorkSafeBC WorkSafeBC

Falls from Formwork (video)

video thumbnail This video demonstrates the importance of proper planning, use of guardrails/work platforms, and the right fall protection equipment. (2 min 12 s)
Source: WorkSafeBC WorkSafeBC

Ladder safety (video)
Source: WorkSafeBCWorkSafeBC Available for loan from WorkSafeBC Library. Call number: V675, DVD14
Available for purchase from WorkSafeBC Store Call number: V675, DVD14.

Ladder Safety in Manufacturing
We use ladders so often that we usually don't think about how to use them safely. But every time you climb a ladder there is potential for an accident. In most cases, falls from ladders can be easily prevented by following the steps outlined in this ebook.
* Interactive ebook

Ladder safety

The ladder safety portal contains hazard alerts, safety talks, and many other resources regarding ladder safety.
Source: WorkSafeBC WorkSafeBC

Booklets & pamphlets
Courses
Regulation & guidelines
Web resources