The safety landscape in manufacturing is being revolutionized through continuous technological advancements. In an industry teeming with inherent risks, this evolution is not just timely but essential. By strategically deploying new technology, manufacturers across the industry are actively reshaping their environments to foster safer, more efficient operations.

Today, we’ll explore the roles of several groundbreaking technologies being employed to bolster safety within the manufacturing sector.


Advanced Technologies Leading the Way In Manufacturing Safety

Industrial Machine Sensors

At the forefront of this manufacturing safety revolution are advanced sensors. These devices can continuously monitor machinery conditions, detecting deviations that could indicate potential failures or hazards. For example, vibration sensors on motors can identify imbalances or misalignments before they result in catastrophic failures, while temperature sensors alert operators when a machine overheats, thereby preventing fire hazards and equipment damage.

A practical application is seen on assembly lines, where industrial machine sensors continuously assess the health of machinery, such as robotic arms. By identifying early signs of wear or malfunction, these sensors enable preventative maintenance before breakdowns occur, improving reliability and offering a measurable return on investment.

Internet of Things (IoT)

The Internet of Things (IoT) enhances machine sensor capabilities by connecting them across a network, facilitating centralized monitoring of equipment throughout a manufacturing plant. This connectivity supports real-time monitoring and predictive maintenance, helping to schedule repairs before hazardous breakdowns.

For instance, in chemical manufacturing plants, IoT devices monitor pressure and chemical levels to prevent dangerous overpressures and leaks.

Artificial Intelligence (AI)

Artificial intelligence (AI) brings sophisticated data analysis to the factory floor, processing vast amounts of data from IoT and sensors. This analysis helps identify patterns that might otherwise go unnoticed, predicting potential equipment failures or unsafe conditions and allowing preemptive risk mitigation.

In manufacturing facilities, AI systems harness this data to proactively adjust machine operations, greatly improving safety and efficiency. Such intelligent use of AI works to minimize disruptions and maintain a secure environment for the workforce.

Robotics and Automation

Robotics and automation can also significantly enhance manufacturing safety. Robots can perform tasks that are too dangerous for humans, such as handling toxic chemicals or working in extreme conditions. This not only reduces human exposure to potential injuries but also increases task precision.

For example, some robots are tasked with handling heavy engine parts installation, a task risky for human workers. These robots reduce the risk of mishaps by making sure components are manipulated accurately and consistently.

Wearable Safety Devices

Wearable technology is quickly becoming a game-changer in manufacturing safety. These devices can be worn by workers to monitor health indicators such as heart rate and fatigue levels, as well as environmental conditions such as toxic gas concentrations or extreme temperatures. This information helps to prevent health-related incidents and prevents workers from being exposed to dangerous conditions.

In high-risk industries such as construction or heavy machinery manufacturing, workers wear smart helmets equipped with sensors that can detect impact or sudden falls and immediately alert safety managers. There are also smartwatches equipped with GPS and biometric sensors that can track workers’ locations and vitals, enabling rapid response in emergency situations.

3 images includng robotics in manufaturing, a worker wearing technology glasses, and a worker looking a manufacturing through augmented reality

Augmented Reality (AR)

Augmented reality (AR) is another transformative technology that improves safety by overlaying digital information onto the real world. Such applications can guide workers through complex tasks and help ensure they are performed safely. AR can also be used for training purposes, providing workers with real-time information and scenarios without the risks associated with live training.

In aerospace manufacturing, AR headsets display assembly instructions directly in the workers’ field of vision, reducing errors and enhancing precision in tasks that require high levels of accuracy. This not only improves safety but also increases efficiency and product quality.

Looking Ahead: The Future of Manufacturing Safety

The integration of technology in manufacturing safety addresses existing challenges and heralds a wave of future advancements. As these technologies continue to evolve, their integration will likely lead to a transformation from reactive to proactive safety management. This progression promises a safer and more efficient future in the manufacturing industry, with ongoing innovation at the core of continuous improvement.

Micah Statler is Director of Industrial Technologies at Advanced Technology Services and is responsible for the strategy, execution and delivery of technology-driven maintenance solutions. Statler is a graduate of Bradley University where he received his Bachelor of Science in Management and Leadership.

Micah Statler

Director of Industrial Technologies, Advanced Technology Services