Safety in Heavy Industry: How Has New Technology Affected the Modern Workplace?

Analyzing data from industrial machines to working environments can only be expected to become even more popular in the future. Machine malfunctions or adverse weather can more easily be anticipated through analytics. Also, monitoring workers' well-being through wearables can help reduce fatigue-related risks.

However, some technical solutions more effectively increase safety than others. From the data, we could establish a hierarchy of technological effectiveness to determine which solutions one should concentrate on:

This graph shows that moving the worker from a potentially hazardous situation can help significantly improve workplace safety. According to the research of Cameron & al. (2018), the increased usage of robotics and automatically driving vehicles, such as drones, can help to reduce workplace-related injuries by up to 11% by 2030. Drones and robotics won't just allow the worker to step away from dangerous situations. These machines can also take care of dull and repetitive tasks. This change, in turn, could help keep workers more alert during the working day and diminish the risk of injuries related to fatigue or carelessness.

Virtual reality helps organizations remain competitive by utilizing modern technology. It also plays a crucial role in enhancing office environments by improving efficiency and productivity.

The next-best options are engineering or admin controls such as sensors and barriers and other data-collecting items like wearables. Digital devices can also help workers pay more attention to safety workflows and procedures in their workplace. Employees can get reminders to wear protective equipment through their wearables or notifications when entering hazardous areas.

The least effective safety technologies are smart PPEs or technology-enhanced personal protective equipment, such as smart helmets, smart glasses, or fatigue monitors. They can send information about workers' well-being straight to managers.

Mapping technology solutions to hazardous situations

Below, based on the framework from the NSC report and further studies and articles on technologies used in manufacturing, construction, transportation, mining, and the oil & gas industry, we've created the following visualization of relevant technologies for each of the most common hazardous situations.

Adopting innovative technology enhances safety and leads to significant cost savings by improving operational efficiencies and reducing expenses. These technologies help businesses analyze usage patterns, adapt real estate needs, and minimize wasted space, ultimately lowering costs. Optimizing resource usage through advanced technologies and IoT devices can significantly improve resource efficiency and contribute to greener office practices.

We've used the hierarchy for the different solutions better to visualize the effectiveness of each solution for each risk.

Users can employ certain technologies to address multiple different risks. For example, as fatigue is a common secondary risk factor in many hazardous situations, wearables for tracking employee fatigue levels are often present in the graphic.

This graphic overviews the technologies available beyond the industries observed in this report. However, as the heavy industries in this study are all unique, we've also illustrated efficient technologies and their use cases individually for each industry. Adopting the right tools to enhance workplace productivity and security is crucial, ensuring that modern workplaces can efficiently mitigate risks associated with remote work and cyber security challenges.

How to make workers safe in the manufacturing industry

Most factories today are partially automated, but the benefits of technology to manufacturing don't stop there. Through IoT sensors, managers can receive real-time data from the machines and be alerted when maintenance work is needed. Advancements in technology have enabled businesses to adopt remote work strategies, allowing for greater flexibility and collaboration. Cloud computing facilitates enhanced data storage, sharing capabilities, and optimized workflows, making it essential for companies to stay competitive and enable flexible work arrangements in today's digital landscape. Leveraging modern technology tailored to specific business needs can significantly enhance workplace operations and overall business value.

Other trends in manufacturing indicate a multitude of different technology solutions. Examples of these are high-technology wearables to monitor workers' posture and the noise level of the factory floor. Another promising possibility is virtual reality programs to train workers to deal with hazardous situations and accidents. Getting clothing or body parts entangled in a machine is extremely dangerous. Wearable sensors can alert workers if they are standing too close to a device or otherwise not following safety protocols.

With fatigue-monitoring wearables, workers can have breaks when needed or have high-concentration demanding tasks when they are the most alert, according to the fatigue data.

Solutions for increasing workplace safety in the construction industry

According to recent studies and research, there is plenty of room for improvement in safety technology in construction. This opportunity exists because the construction industry generally lags behind other industries in technology adoption. However, the industry can benefit from different technologies in multiple ways, presented in the graphic below.

Organizations can use VR training to train workers about complex or dangerous tasks. Doing so would better prepare them and decrease the risk of accidents and injuries. Working remotely has evolved from an uncommon practice to a mainstream norm post-pandemic, impacting office culture and employee interactions in the construction industry. Innovative technology has enabled greater flexibility, attracting a wider talent pool while reducing operational costs. Hybrid working has emerged as a standard practice, necessitating organizations to adapt their strategies to accommodate both in-office and remote employees.

Software such as 3D/4D computer-aided design (CAD), building information modeling (BIM), and laser scanning can help identify hazards from afar.

Proximity sensors can reduce the risk of collisions or falls. This technology can alert workers when an object, such as a piece of machinery or a person, enters set proximity.

Location geofencing detection can alert workers when entering a potentially dangerous worksite zone. This limits accidents arising from disregarded safety procedures in high-risk areas. Work zone intrusion detection will alert workers if unauthorized people enter the work area without permission.

Robotics and automation, such as crewless aerial vehicles, can be used when work needs to be done high above the ground.

Wearables can monitor lone workers, prevent collisions with machines, and help find all employees faster in an emergency. They can also help prevent or reduce health risks from exposure to high temperatures during hot work for too long. Remote collaboration enhances communication and teamwork, making it more interactive and integrated into everyday work processes.

Workplace safety solutions in the transportation industry

The most used safety technologies in transport are sensors, cameras, and devices monitoring obstacles and speed.

Also, in transportation, eliminating the human factor with crewless vehicles such as connected vehicles (CV) or automated vehicles (AV) can significantly reduce road accidents. Organizations in the industry can employ software installed in cars. The software will help stop drivers from using digital devices and demand them to stop for breaks.

Key data needed for crossing borders can be saved conveniently on digital devices, helping avoid stress and long waiting periods at customs while benefiting the worker's well-being.

Also, VR training can prepare drivers for various hazardous driving scenarios and protect them in dangerous situations on the road. Adopting new workplace technologies can significantly enhance worker productivity by improving operational efficiency and creating an engaging and adaptive work environment. Additionally, technological advancements have significantly enhanced the customer experience by improving communication and collaboration within teams, which in turn helps improve productivity.

Technology solutions for workplace safety in the mining industry

For mining, the most mentioned and most effective technologies are the ones that can help to remove the workers from potentially hazardous situations or to alert them.

Worksite simulators can provide training without exposing inexperienced workers to hazardous environments.

Robotics and automation, such as self-driving trucks or robotic drills, enable workers to avoid hazardous situations and environments. Drones can take images inside mines in areas with the risk of collapse and replace labor-intensive survey, inspection, or mapping activities.

Sensors and monitors can also help make mining safer. By monitoring rock movements, workers can receive warnings regarding potentially dangerous seismic activity. Radar can identify workers underground and assist in planning drilling and controlled demolitions. Monitoring usage patterns of heavy equipment through radio-frequency identification can aid the scheduling of part replacement, fluid change, or maintenance optimization.

Wearables can also benefit workers in multiple ways. They can detect environmental hazards, including poor air quality, and emit a warning signal early on for potentially harmful or dangerous situations. They can also help locate workers in mines during an emergency and keep tabs on their fatigue levels. Project management software helps organize tasks and align teams, ensuring all safety protocols are followed efficiently.

Making the oil & gas industry safe for workers

As in other industries, drones and robotics can help prevent accidents while extracting oil and gas. They can be used, for example, in oil tank inspection or other dangerous maintenance jobs, to get a better overview of the site.

IoT can be used to gather data from machines and keep an eye on performance. Monitors can be placed on-site to track the levels of hazardous gases in the air. Environmental monitoring is essential in confined spaces. Additionally, the oil and gas industries' GPS systems and other wearables can help to track employees' location and well-being on-site, even onshore.

Special attention has also been given to vehicle collisions. These make up a significant proportion of accidents in the industry due to the long distances involved. Technologies like radar, 360-degree cameras, digital device usage-blocking software, or fatigue-tracking wearables can help improve safety when driving from site to site. Strategic work enabled by these technologies allows employees to focus on more value-added activities, enhancing engagement and productivity.

Requirements for technological solutions to be used in hazardous environments

The heavy industries studied in this report pose specific strains for people and the equipment used in the industries. EHS professionals interviewed in the NSC survey were especially concerned about the different technologies' adaptability to their industries' special requirements. Thus, equipment used in these working environments must be equipped for unique stresses.

Additionally, protecting sensitive data in these hazardous environments is crucial. Businesses must implement strong security measures and technology solutions to securely manage and store sensitive information while adhering to compliance regulations. Addressing data privacy is essential when adopting new technologies in these environments to ensure the security and integrity of organizational information. To stay ahead, businesses need to embrace and strategically implement new technologies to maintain a competitive edge and meet the demands of their customers effectively.

Robustness and durability are vital

First, devices must be robust and able to take hits or drops. Of course, when a person accidentally falls from a height, what happens to the device they carry is unimportant. Workers who know their device can withstand a fall may not be as likely to try to catch it. However, the instinct to try to catch a falling, expensive device poses a risk of them falling after it themselves.

Devices must also work correctly in diverse conditions. A mine or construction site can be filthy and loud. Therefore, the products used in these environments must withstand dust, sand, vibrations, and moisture build-up. Additionally, there might be minimal sunlight coverage at oil fields or construction sites. For workers to follow visually-prompted instructions, the screen must be bright enough to be visible under direct sunlight. Robust and durable technology in the workplace is essential for ensuring efficiency and safety in such challenging environments

Regulatory compliance

All workplaces must comply with the laws and regulations of the country where they operate. The European Union also has a list of directives related to safe and healthy working environments, which its member states must consider. Integrating third-party systems is essential for achieving and maintaining compliance with these regulatory requirements.

The workplaces in the industries chosen for this study can also be classified as hazardous work environments. Working in mines, on oil rigs, or transporting dangerous substances such as gasoline poses an increased health and safety risk for the workers, making it crucial that equipment used in these environments doesn't add to that risk.

For example, all products and equipment used in hazardous environments with potentially explosive atmospheres must be certified in America and Europe. Certificates such as UL and C-UL in North America and ATEX in Europe ensure products are used in workplaces with potential fire or an explosion.

Technologies must lighten the load, not increase it

Safety products cannot get in the way of everyday work. They should be light and easy to carry in a tight mine elevator or climb a construction ladder. Employees also must use or wear them alongside their regular safety gear. Items like touch screens must be usable while wearing gloves.

In hazardous environments, teams must communicate back and forth, below and above ground (mines) or on land (oil rigs). The devices one uses must have long battery life and strong WiFi/4G/LTE signal. In environments where getting a signal is impossible, other ways of transporting data and information, such as Bluetooth, must be standard.

Whether deep in a mine, at elevation on a construction site, or with a flat tire in the middle of nowhere, employees must be reachable and not struggle with their devices. GPS makes it possible to track employees, especially if they need to work alone, further increasing worker safety.

Additionally, addressing cybersecurity risks is crucial when using technology in these hazardous environments to ensure the safety and security of both data and personnel. The increasing complexity and number of cyber threats associated with technological advancements necessitate strong cybersecurity measures and training. By minimizing time-consuming processes, organizations can enhance productivity and allow employees to concentrate on more strategic business activities.

Using different technologies is just the beginning of improving workplace safety

It's impossible to prevent workplace-related injuries completely. However, several technologies are available for companies of different sizes to improve workplace safety. Digital tools enhance productivity and efficiency by automating once-manual processes, allowing organizations to focus more on safety measures. Additionally, employees can choose flexible working arrangements, including the traditional office, to better fit their lifestyles and job roles amid the rise of hybrid working models.

Many of the most effective technologies for preventing workplace injuries aim to remove the worker from the dangerous task altogether. Automation replacing human workers is often perceived rather negatively. However, it should be welcomed in cases where it can improve workplace safety.

However, technology has its limits. Many injuries result from human error, such as negligence of safety procedures or fatigue. Monitors, wearables, and reminder apps can help workers remember to use their protective gear. Such devices enable managers to monitor employee levels of alertness. However, it's the managers' job to organize shifts and working procedures to ensure employees stay as safe and alert as possible.

Similarly, it's the managers' job to ensure workers have the necessary skills, as insufficient and inadequate training poses a significant risk. Something unexpected can always happen, but one can be prepared thanks to technology. With virtual and AI training, workers can safely practice for hazardous situations and be ready if something goes wrong.

Lastly, new technologies must adapt to different industries' specific needs and requirements. The devices must comply with the rules and regulations set by other countries, states, and global organizations. These devices can't become risk factors, for example, in explosive environments. Manufacturers of these technologies must be aware of all these risks and what these environments are like to improve workplace safety. Integrating workplace technology is crucial to staying competitive and efficient in a rapidly changing digital landscape.

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