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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
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 
* Available for purchase from the WorkSafeBC store.
Due Diligence (video)
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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) |
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Source: WorkSafeBC | |
Confined Spaces
Confined Spaces: Safe Yesterday, Deadly Today (1 of 3) (video)
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Identify the confined spaces in your workplace as a first step in reducing their hazard. (3 min 22 s) |
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Source: WorkSafeBC
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Confined Spaces: Test to Live (2 of 3) (video)
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Test the atmosphere before entering a confined space. It can make the difference between life and death. (3 min 38 s) |
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Source: WorkSafeBC
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Confined Spaces: Rescue - Just Calling 911 Doesn't Cut It (3 of 3) (video)
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Successful rescue requires proper planning, training, equipment, and practice. (3 min 04 s) |
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Source: WorkSafeBC
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Confined spaces: deadly spaces (video)
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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) |
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Source: WorkSafeBC
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Precious Time - The Cody McNolty story (video)
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This video contains language that may be offensive to some, viewer discretion is advised.
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Source: WorkSafeBC
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Hazards of Confined Spaces (PDF 596 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. These spaces may also have physical hazards that may result, for example, in workers falling, being crushed or buried, or drowning. These hazards may not be obvious. All confined spaces must be carefully assessed to identify any hazards."
Source: WorkSafeBC
* Available in print from Publications, Videos and Forms Distribution.
Ergonomics
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.
- Ergonomics: Awkward Postures (PDF 264 KB)
- Ergonomics: Contact Stress (PDF 240 KB)
- Ergonomics: Forceful Exertion (PDF 416 KB)
- Ergonomics: Repetition (PDF 220 KB)
- Ergonomics: Static Postures (PDF 324 KB)
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. Each section of the publication examines common risks associated with certain body movements and job tasks, and identifies ways to eliminate or minimize them in a manufacturing setting. Also included is information on the Ergonomics (MSI) Requirement from the BC Occupational Health and Safety Regulation.
Source: WorkSafeBC
* Available in print from Publications, Videos and Forms Distribution.
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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. |
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Source: WorkSafeBC
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Push / Pull / Carry Calculator
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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. |
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Source: WorkSafeBC
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Elements of Ergonomics Programs
"This primer describes the basic elements of a workplace ergonomics program. The text is largely built around NIOSH experiences in evaluating risks of WMSDs in a variety of workplaces."
Source: NIOSH (National Institute for Occupational Health and Safety)
Ergonomics
Ergonomics is matching the job to the worker and product to the user. Ergonomics and human factors are often used interchangeably in workplaces.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)
ErgoWeb Reference Materials
Links to a very large number of online ergonomics resources.
Source: ErgoWeb
OSH Answers: Hand Tool Ergonomics
Information on the following topics presented in question-and-answer format: Health Hazards, Introduction, Job Design, Tool Design, Workspace Design.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)
OSH Answers: Pushing and Pulling - General
Information presented in question-and-answer format.
Source: CCOHS (Canadian Centre for Occupational Health and Safety)
Back Talk: An Owner's Manual for Backs BK4 (PDF 621 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.
Source: WorkSafeBC
Updated: June 2007
* Available in print from Publications, Videos and Forms Distribution.
BackCare The National (UK) Organisation for Healthy Backs
A website which helps people manage and prevent back pain by providing advice, promoting self help, encouraging debate and funding scientific research into better back care.
Source: BackCare
Visit the ergonomics web pages for more information.
Hearing Protection
The Hearing Video
(video)
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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) |
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Source: WorkSafeBC |
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Deaf to the Danger: Packing Plant Scenario (video)
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This video demonstrates the dangers associated with wearing earbuds on the job in a packing plant. (1 min 25 s) |
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Source: WorkSafeBC |
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Deaf to the Danger: Warehouse Scenario (video)
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This video demonstrates the dangers associated with earbuds on the job in a warehouse. (1 min 23 s) |
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Source: WorkSafeBC | |
Hear for good: Preventing exposure at work (PDF 1 MB)
"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
* Available in print from Publications, Videos and Forms Distribution.
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)
Lockout
Lockout: a guide to safe work practices (video)
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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) |
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Source: WorkSafeBC | |
Lock out. It takes just seconds to lose a limb.
(slide show)
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This slide show describes two accidents, each where a worker lost a limb following improper lockout. (2 min 58 s) |
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Source: WorkSafeBC | |
Lockout for Woodworking
(slide show)
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De-energizing woodworking machinery when doing maintenance prevents injury. See the basic steps for locking out. (2 min 42 s) |
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Source: WorkSafeBC |
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Lockout BK21 (PDF 2.4 MB)
This booklet defines lockout, explains lockout policy and procedures, and provides guidance on compliance with Regulation requirements.
Source: WorkSafeBC
* Available in Simplified Chinese,
Traditional Chinese,
Punjabi,
Spanish, and
Vietnamese.
* Available in print from Publications, Videos and Forms Distribution.
Machinery and Equipment
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
Fields of Vision: Pedestrian Safety around Forklifts (video)
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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) |
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Source: WorkSafeBC | |
Forklift crushes worker (slide show)
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Don't rely on just the parking brake. Lower the forks before exiting the cab. (2 min 59 s) |
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Source: WorkSafeBC | |
Forklift tips over, crushing operator (slide show)
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Slide show of an accident investigation where a forklift operator died when his forklift tipped over. (1 min 52 s) |
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Source: WorkSafeBC | |
Safe Operation of
Lift Trucks (PDF 86 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.
Source: WorkSafeBC
* Available in print from Publications, Videos and Forms Distribution.
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)
Personal Protective Equipment (PPE)
Look at me (video) 
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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) |
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Source: WorkSafeBC |
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Fall Protection (video)
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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) |
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Source: WorkSafeBC |
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An Introduction to Personal Fall Protection Equipment BK60 (PDF 545 KB)
This booklet outlines the safe use and limitations of personal fall protection equipment.
Source: WorkSafeBC
* Available in Simplified Chinese,
Traditional Chinese,
Punjabi, Spanish, and Vietnamese.
* Available in print from Publications, Videos and Forms Distribution.
Breathe Safer: How to use respirators safely and start a respirator program (PDF 2 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
* Available in print from Publications, Videos and Forms Distribution.
Updated: January 2005
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.
Safeguarding
More than 25% of the injuries in the manufacturing sector are caused by poor or missing safeguarding. The following links list tools, publications, and other resources to help improve safeguarding at your workplace.
Too Much Too Lose (video)
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An experienced worker loses his fingers when he uses a dangerous piece of equipment without a guard. (3 min 12 s) video guide (PDF 252 KB) |
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Source: WorkSafeBC |
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Guarding
(video)
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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) |
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Source: WorkSafeBC |
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Guarding for Woodworking
(slide show)
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Effective point-of-operation safeguarding and safe work practices can help to prevent serious injuries when using table and panel saws. (4 min 40 s) |
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Source: WorkSafeBC |
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Virtual Conveyor (Flash video--requires the Macromedia Flash plug-in.) This link leads to an animated site that shows the hazards associated with conveyor systems and presents some possible solutions to the lower the risk associated with those hazards. Source: CSST (Commission de la santé et de la 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
Publications
Safeguarding Machinery and Equipment: General Requirements (PDF 4.6 MB)
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.
* Available in print from Publications, Videos and Forms Distribution.
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 |
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Section 1 (PDF 611 kb) |
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Section 2 (PDF 120 kb) |
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Section 3 (PDF 2.1 mb) |
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Section 4 (PDF 424 kb) |
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Section 5 (PDF 629 kb) |
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Section 6 (PDF 435 kb) |
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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
* Available in print from Publications, Videos and Forms Distribution
For your convenience and ease of use, each section of this infoflip is also available as a stand-alone PDF (8.5" x 11"). The following sections present the same information in the infoflip, organized by the same number and colours used in the infoflip.
| Introduction | Intro (PDF 92 kb) |
| 1. Overview and Terminology | Section 1 (PDF 392 kb) |
| 2. Hazard Recognition | Section 2 (PDF 290 kb) |
| 3. Risk Assessment | Section 3 (PDF 96 kb) |
| 4. Selecting the Right Safeguard | Section 4 (PDF 99 kb) |
| 5. Barrier Guards | Section 5 (PDF 420 kb) |
| 6. Power Transmission Guards | Section 6 (PDF 461 kb) |
| 7. Grid Guard Design Considerations | Section 7 (PDF 198 kb) |
| 8. Protective Barriers | Section 8 (PDF 141 kb) |
| 9. Two-Hand Controls and Trips | Section 9 (PDF 235 kb) |
| 10. Presence-Sensing Devices | Section 10 (PDF 392 kb) |
| 11. Safety Interlocks | Section 11 (PDF 145 kb) |
| 12. Movable Gates | Section 12 (PDF 434 kb) |
| 13. Pull-Wires / Trip-Wires / Contact Bumpers | Section 13 (PDF 283 kb) |
| 14. Shields / Awareness Barriers | Section 14 (PDF 457 kb) |
| 15. Safeguarding by Location | Section 15 (PDF 169 kb) |
| 16. E-Stops | Section 16 (PDF 533 kb) |
| Zip archive containing all the above files (requires zip utility to decompress) |
Zip archive (ZIP 6.4 mb) |
Machine Safety - Prevention of mechanical hazards (PDF 12 MB)
This guide, published by IRSST, describes the use of safeguarding to eliminate or reduce hazards in the manufacturing sector. Although the guide references 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)
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
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
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
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
Self-Assessment Forms for Occupational Health & Safety (HTML)
These forms were that were developed as a joint initiative by the Institut de recherche Robert-Sauvé en santé et en sécurité du travail (IRSST) and the Association paritaire Secteur fabrication du produits en metal et de produits electriques (ASPME). IAPA has translated the forms into English for use by employers, supervisors, workers and or health and safety committees.
Source: IAPA (Industrial Accident Prevention Association Ontario)
Hazard alert posters
- 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
- OHS Regulation Part 12 Tools, Machinery and Equipment
- OHS Guidelines Part 12 Tools, Machinery and Equipment
Slips, Trips and Falls
Multimedia
Housekeeping in Woodworking
(slide show)
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Prevent slips, trips, falls, and injuries in your woodworking shop through simple housekeeping techniques. (1 min 46 s) |
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Source: WorkSafeBC | |
Young construction worker dies from fall
(slide show)
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Prevent slips, trips, falls, and injuries in your woodworking shop through simple housekeeping techniques. (3 min 1 s) |
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Source: WorkSafeBC | |
Falls from ladders
(video)
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Prevent slips, trips, falls, and injuries in your woodworking shop through simple housekeeping techniques. (2 min 0 s) |
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Source: WorkSafeBC | |
Falls through Openings
(video)
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This video demonstrates the importance of proper planning, use of guardrails, and the right fall protection equipment. (1 min 41 s) |
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Source: WorkSafeBC | |
Falls from Top Plate
(video)
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This video demonstrates the importance of proper planning, use of guardrails/work platforms, and the right fall protection equipment. (2 min 6 s) |
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Source: WorkSafeBC | |
Falls from Formwork
(video)
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This video demonstrates the importance of proper planning, use of guardrails/work platforms, and the right fall protection equipment. (2 min 12 s) |
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Source: WorkSafeBC | |
Ladder safety (video)
Source: WorkSafeBC
Available for loan from WorkSafeBC Library. Call number: V675, DVD14
Available for purchase from WorkSafeBC Store Call number: V675, DVD14.
Bulletins
Construction Safety SeriesThis 12-page booklet focuses on ladder safety and fall protection for residential construction.
- Safety Tip 1: Ladder Set-Up
- Safety Tip 2: Ladder Use
- Safety Tip 3: Stepladder Use
- Safety Tip 4: Extension Ladder Use
Checklists
Hazard alerts
- Worker dies after slipping on frost and falling from roof
- Young worker seriously injured in fall through roof opening
- Hazards of Working from Fixed Ladders on Tanks
- Falls from stepladders can kill
Toolbox meeting guides
Signs & stickers
- Secure This Ladder Before Using (PDF 52 KB)
- 4 To 1 Ratio For Safety (PDF 51 KB)
Booklets & pamphlets
Courses
Regulation & guidelines
- OHS Regulation Part 13: Ladders, Scaffolds & Temporary Work Platforms
- Guidelines Part 13: Ladders, Scaffolds & Temporary Work Platforms
- WCB Standard: LDR 1-2004 Job Built Ladders
Web resources
- Preventing slips and trips at work (PDF 631 KB) Source: Health & Safety Executive
- Foot Comfort and Foot Safety at Work Source: CCOHS
- Ladders Storage and Handling Source: CCOHS
- What should you know about portable ladders before using them? Source: CCOHS
- Inspecting Ladders (CCOHS) Source: CCOHS
Young Worker
Young Workers in Manufacturing (video)
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Michael Lovett lost his leg in a sawmill accident in 1999. He was just 18 years old. In this short video, Michael and a WorkSafeBC officer provide a perspective on what employers can - and should - do to prevent more tragedies like this. ( 6 min 39 s) |
Training and orientation for young and new workers (PDF 141 KB)
An employer's guide to the amendments in Part 3 of the Occupational Health and Safety Regulation
Source: WorkSafeBC
Visit the young worker web pages for more information.
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