Manufacturing risk management
Guidance on machine guarding, lockout/tagout, OSHA compliance, ergonomics and injury prevention — the programs that reduce workers' comp claims, avoid fines and keep your workforce safe.
Why manufacturing risk management matters
Manufacturing facilities have some of the highest injury rates of any industry. Heavy machinery and moving parts, chemical exposures and repetitive-motion work create significant hazards.
Manufacturers with strong safety cultures consistently see fewer injuries, lower insurance costs, higher productivity and better retention. The programs below are the ones leading manufacturers use. For more, see standards from OSHA, research from NIOSH and training resources from the National Safety Council.
All manufacturing guides
Start with the featured guide, The Complete Guide to Machine Guarding, then explore the topics that fit your operation.
The Complete Guide to Machine Guarding: OSHA Requirements and Best Practices
Learn essential machine guarding tips from our comprehensive Machine Guarding Guide to enhance workplace safety and compliance.
Learn more →Lockout/Tagout (LOTO): Preventing Deadly Energy Release
Get comprehensive insights on Lockout Tagout strategies to effectively manage hazardous energy and safeguard your employees.
Learn more →Forklift Safety: Training, Certification, and Pedestrian Protection
Enhance your knowledge on Forklift Safety with our comprehensive guide covering training, hazards, and operational best practices.
Learn more →Building an Ergonomics Program: Preventing Musculoskeletal Disorders
Enhance workplace safety with an Ergonomics Program that reduces musculoskeletal disorders and boosts productivity in manufacturing.
Learn more →PPE Programs: Selection, Training, and Compliance
A well-designed PPE program is crucial for workplace safety. Find out how to select, fit, and maintain personal protective equipment.
Learn more →Hazard Communication: GHS Labels, SDS, and Employee Training
Understand Hazcom GHS and its role in ensuring workplace safety in manufacturing environments with standardized communication practices.
Learn more →New Employee Safety Orientation: Building Safe Habits from Day One
New Employee Safety is crucial in manufacturing. Learn how to reduce injury rates with a comprehensive safety orientation program.
Learn more →Slip, Trip, and Fall Prevention in Manufacturing Facilities
Prevent costly workplace injuries with effective slip trip fall techniques. Learn how to enhance safety in manufacturing facilities.
Learn more →Confined Space Entry: Permit Programs and Rescue Planning
Explore crucial tips on managing Confined Space hazards in manufacturing and protect workers with effective safety measures.
Learn more →Fire Prevention and Emergency Response in Manufacturing
Understand the critical importance of fire prevention in manufacturing operations to maintain safety and prevent financial damage.
Learn more →Workers Compensation Claim Management: Reducing Costs and Duration
Explore Workers Comp Management strategies that can lower claim costs dramatically and streamline your claims process efficiently.
Learn more →Building an Effective Safety Committee for Manufacturing
Building an effective safety committee transforms your manufacturing facility from reactive to proactive when it comes to workplace safety. Companies with…
Learn more →Hearing Conservation Programs: Protecting Workers from Noise
Explore the necessity of Noise Hearing Conservation programs to ensure worker safety and compliance with health regulations.
Learn more →Incident Investigation: Finding Root Causes to Prevent Recurrence
Effective incident investigation transforms workplace accidents from costly setbacks into powerful opportunities for improvement. When injuries or…
Learn more →Job Hazard Analysis: Identifying Risks Before Injuries Occur
Understand Job Hazard Analysis and discover how it greatly reduces workplace injuries by identifying hazards before they cause harm.
Learn more →Pallet Rack Safety: Inspection, Load Limits, and Damage Prevention
Prevent costly warehouse rack collapses with proper inspection, load management, and damage prevention. Contact us.
Learn more →Warehouse Safety Inspections: Building a Culture of Compliance and Care
Learn how effective Warehouse Safety Inspection can safeguard employees and help maintain regulatory compliance in warehouses.
Learn more →Free manufacturing resources
Machine Guarding Audit Checklist (PDF)PDFLOTO Procedure Template (PDF)PDFJob Hazard Analysis Template (DOCX)DOCXMore guides on this topic
Access Control for Warehouses: Zones, Doors, Docks and Credentials
How to set up warehouse access control: zones, dock and door security, badges and keys, driver check-in, OSHA exit rules, and how insurance typically
Learn more →Warehouse Theft Prevention: Internal, External and Fraudulent Pickups
How to stop the three ways warehouse inventory disappears: employee theft, burglary and yard theft, and fictitious pickups, plus how coverage responds
Learn more →Warehouse Ergonomics: Preventing Strains, Sprains and Lifting Injuries
Reduce warehouse strains and sprains: OSHA and Washington rules, the NIOSH lifting equation, controls that work, early reporting, and how workers comp
Learn more →Warehouse Fire Prevention: Ignition Control, Sprinklers and Storage
Warehouse fire prevention: NFPA data, ignition control, keeping storage within sprinkler design, the 18-inch rule, egress, and how property coverage r
Learn more →Protecting Inventory from Loss: Fire, Water, Theft and Spoilage
How to protect inventory from fire, water, theft, spoilage and transit loss, keep records that support a claim, and spot common gaps in stock coverage
Learn more →Need manufacturing insurance?
From workers' compensation to product liability, we compare options across the market and shape coverage around what you make and how.
These guides are general educational summaries and are not legal, tax or coverage advice, a statement of coverage, an offer or a binder. Statistics are industry figures cited for context and may vary by source, sector and year. Coverage, limits and eligibility are governed by the terms, conditions and exclusions of the policies issued and are subject to underwriting.