Safety first: Essential personal protective equipment for industrial settings

in English

The industrial workplace, characterised by intricate processes and high-tech environments, demands precision and safety at every turn. Workers in this sector are often exposed to hazards, including electrostatic discharge (ESD) risks and chemical exposure, which can damage sensitive equipment and pose significant health risks.

Despite advancements in safety protocols, incidents related to inadequate personal protective equipment (PPE) continue to occur. These incidents are often due to a lack of understanding of the specific PPE needs in the manufacturing workplace, resulting in equipment failure, injuries, and costly downtime.

How can the manufacturing industry better address these specific PPE requirements to mitigate risks, protect workers, and ensure smooth operations?

This article explores the critical role of PPE in the workplace. It provides a detailed overview of the essential equipment, best practices, and strategies for integrating PPE into safety protocols. Organisations can significantly enhance workplace safety, protect valuable equipment, and maintain high operational standards by understanding and implementing the correct PPE.

Addressing safety challenges and PPE needs for industrial hazards

In any manufacturing environment, employees face a variety of hazards that can lead to severe injuries or illnesses, making PPE essential as a final line of defence. These challenges range from operating dangerous machinery to handling hazardous chemicals and enduring high noise levels, all of which pose significant risks to health and safety. To effectively protect against these dangers, workers must use appropriate PPE. The following are some of the most critical hazards that necessitate the use of PPE:

Hazardous substances: Solvents, adhesives, and fluxes can be harmful if they come into contact with skin or are inhaled.
Electrical risks: Electric shocks and potential fires, especially during manufacturing and testing processes, make electrical safety a priority.
Acoustic hazards: Prolonged exposure to loud sounds can lead to permanent hearing damage, highlighting the need for hearing protection.
Thermal dangers: Machines that operate at high temperatures pose risks of burns and heat-related illnesses, requiring appropriate thermal protection.
Electrostatic discharge: ESD can damage sensitive components, cause painful shocks, and even trigger explosions or fires in flammable areas.
Airborne contaminants: Inhaling micro particles and dust can lead to respiratory issues, making respiratory protection essential.

Importance of safety in the industrial environment

Industrial safety focuses on minimizing various hazards that can lead to individual injuries or health risks. With millions of accidents annually, industries worldwide prioritise safety measures to protect workers and assets. Critical considerations in industrial safety include:

Avoiding accidents: It is crucial for protecting employees, property, and the environment. Proper training, safety equipment, and clear protocols reduce risks, prevent disasters, and enhance profitability. Unsafe conditions, on the other hand, can damage public trust and hurt business.
Greater productivity: Prioritizing safety considerably increases production, dispelling the myth that safety measures impede performance. A strong safety culture encourages proper practices, reducing mishaps and production disruptions. Finally, a commitment to safety encourages a more efficient and successful workforce.
Legal compliance: Ensuring workplace safety is a moral duty and a legal necessity, with governments worldwide enforcing strict regulations to minimize the risk of accidents. These standards, such as the Occupational Safety and Health Administration (OSHA) in the U.S. or the EU's Safety and Health at Work directives, compel companies to prioritise safety by implementing protective measures, providing appropriate equipment, and maintaining a secure working environment. ISO 45001 also offers a systematic approach to preventing workplace injuries and promoting safe, healthy working environments. Failure to comply can lead to severe consequences, including hefty fines, operational shutdowns, and even criminal charges against negligent employers.

Factors to consider when selecting the PPE

When selecting PPE for different industrial settings, consider the following key factors:

Assessment of workplace hazards: A thorough hazard assessment is crucial for selecting the right PPE, which should be tailored to the specific risks present in each environment.
Correct fit and comfort: Proper fit and comfort of PPE are crucial for safety and compliance, as ill-fitting can increase injury risks and distract workers. PPE, such as respiratory masks and safety footwear, must be tailored to individual needs to prevent leaks, nerve damage, and discomfort, ultimately enhancing workplace safety and productivity.
Compliance with safety standards: Regulatory compliance is crucial when selecting PPE, as it must meet relevant safety standards, such as those set by OSHA or the American National Standards Institute (ANSI). Each industry may have specific regulations, and it is crucial to consider local laws and industry-specific requirements to ensure full compliance and worker safety.
Training and education on proper PPE usage: Employees must be trained before performing tasks that require PPE, demonstrating their understanding and appropriate use. Training should cover identified hazards, specific PPE requirements (type, material, size, and ratings), proper fit and wear, and PPE limitations. Additionally, workers should be educated on the appropriate care, maintenance, inspection, useful life, and disposal of PPE.

Effective PPE solutions for safety challenges

PPE is essential for safeguarding employees from health and safety hazards in the workplace. It is also a legal requirement for companies to provide suitable PPE tailored to the specific dangers of the work environment. In the electronics industry, various types of PPE are widely used throughout the design, manufacturing, quality control, and packaging stages to ensure worker safety. The following are some key categories :

Head protection: This is critical in any safety program because head injuries can lead to lifelong impairment or even fatalities. The simple and most effective way to shield employees from impact, penetration, electrical shock, and burn hazards is to wear safety helmets or hard hats.
Figure 1: METEOR 2185 ELECTRONIC HEADSHIELD (Source)
Eye and face protection- Safety goggles and face shields protect the eyes and face from chemical splashes, dust, and flying debris, with additional protection from laser radiation when needed.
1. Safety glasses: These come with side shields or goggles to guard against flying debris and sparks. They can be designed with corrective lenses or fit over prescription glasses.
2. Goggles: Made from flexible plastic, goggles provide all-around protection and can fit over corrective lenses, although some may not be suitable for gases and fine dust.
3. Face shields: These shields feature a large lens and adjustable harness, protecting the face but not fully enclosing the eyes. They can be worn with prescription glasses.
4. Welding shields: Constructed from vulcanized fibre or fibreglass with a filtered lens, these shields protect against intense light and flying sparks during welding, brazing, and cutting. OSHA mandates appropriate shade filters to guard against harmful radiation.
Figure 2: Face Shield with Chin Guard - Clear Visor (Source)
Hand and arm protection: When hazards to hands and arms cannot be fully eliminated through engineering or safe work practices, employers must ensure that workers wear appropriate protective gear. PPE, like gloves, guards, and sleeves, is essential for protection against a wide range of risks, including chemical exposure, burns, cuts, electrical risks, and even amputations. Specialized gloves and sleeves provide targeted protection, such as ESD-safe gloves for handling sensitive components.
1. Insulated Gloves: Made from rubber or other insulating materials to protect against electric shock.
2. Rubber Lineman Gloves: Offer extra insulation for high-voltage electrical work.
3. Sleeves: Insulating materials that cover the arms for added electrical protection.
  Types of gloves include:
  (a) Standard gloves for hand protection,
  (b) Gloves with cuffs for hand and wrist,
  (c) Gauntlets or long gloves for the hand, wrist, and part of the forearm,
  (d) Sleeving for forearm and upper arm protection.
Figure 3: SCRUFFS T51009 Thermal Gloves (Source)
Hearing protection: The louder the noise, the less time you can safely be exposed without protection. For instance, workers can handle 90 dB noise levels for up to 8 hours a day without protection. However, at 115 dB, hearing protection is a must after just 15 minutes of exposure. Hearing Protection Options:
1. Earplugs: Made of foam or other materials, these protect ears from excessive noise when working with loud equipment.
2. Earmuffs: Used alongside earplugs, earmuffs provide additional protection against high noise levels to safeguard workers' hearing.
Figure 4: Ear Defender, Earmuff, 3 dB Deviation, 27 dB Attenuation (Source)
Foot and leg protection: Safety shoes or boots safeguard against electrical hazards, sharp objects, and chemical spills and offer slip resistance. Employees facing potential foot or leg injuries from falling, rolling, crushing, or penetrating materials should wear protective footwear. Protective gear covering exposed body parts, including legs and feet, is essential when working with hot, corrosive, or poisonous substances. Non-conductive footwear is required for electrical hazards, while conductive footwear may be necessary for static electricity exposure. Here is some of the examples-
1. Safety shoes: The most common protective footwear features non-conductive soles for electrical shock protection and insulation. They have protective toecaps and safety elements like slip-resistant soles, penetration-resistant midsoles, and insulation against extreme temperatures.
2. Dielectric overshoes: Made of non-conductive materials worn over regular footwear for added electrical insulation.
3. Wellington boots: Usually made of rubber for wet conditions or jobs requiring frequent washing and disinfection.
4. Clogs: Traditionally made from beech wood, they can be fitted with steel toecaps and thin rubber soles for quieter treads.
5. Specialty footwear: Designed for specific tasks, such as foundry and chainsaw boots.
Figure 5: TITANIUM SAFETY BOOT, WHEAT, 10 (Source)
Body protection: Employees facing potential bodily injury must wear appropriate protective clothing while performing their jobs.
1. Ergonomic clothing: Anti-static, flame-resistant, and chemical-resistant clothing designed for comfort and ease of movement while offering protection against hazards like chemical exposure, heat, and static electricity.
2. Flame-resistant clothing: Made of non-conductive materials like cotton to reduce burn risks from arc flashes or electrical fires.
3. Arc flash suits: These consist of flame-resistant jackets, pants, hoods, or face shields to protect against arc flash thermal effects.
Figure 6: ST 35426 HI-VIS JACKET (Source)
Respiratory protection is essential for workers exposed to harmful substances and pollutants. Respirators filter out dangerous contaminants from the air, protecting users from inhaling toxicants. These devices can filter noxious substances (like N95 masks) or supply clean air from another source. While face masks are considered PPE, they are not classified as respirators.
1. Respiratory masks are crucial when handling hazardous materials, from vapours to fine dust particles. Whether using dust masks for particulate matter or full-face masks for toxic substances, respiratory protection is vital for safeguarding against pollutants.
Figure 7: 3M 7502 respirator (Source)
Figure 8: Essential protective gear for workplace hazard prevention (Source)

Conclusion

In the ever-evolving world of manufacturing, safety should always come first. Personal protective equipment is essential for protecting workers from the numerous hazards they face daily. Companies should establish and maintain efficient PPE programs to protect employees, ensure regulatory compliance, boost productivity, and strengthen their market reputation. With increasing awareness and the enforcement of regulations, protecting individuals from occupational hazards has become mandatory in industries that rely on PPE kits as a safety measure against possible and unavoidable hazards.