PLANT MACHINERY & SITE SAFETY
SENSING AN OPPORTUNITY
Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply specialist Swindon Silicon Systems, explains how sensors address three of the top safety hazards in manufacturing.
Workplace safety has come a long way since the rollout of mass manufacturing in the Industrial Revolution, thanks to stronger regulations, better training and automation. However, the Health and Safety Executive’s latest report revealed the industry still ranks among the top three sectors for work-related fatalities, behind construction and agriculture.
IDENTIFYING PERSISTENT DANGERS While the baseline for operational safety may have improved, serious risks remain on the factory floor.
One of the most longstanding risks relates to machine guarding. Heavy machinery used in manufacturing often relies on physical barriers to shield workers from dangerous moving parts. Ironically, when these guards are faulty, improperly installed or deliberately bypassed, they become a hazard in their own right – leaving operators exposed to high-speed components capable of causing serious injury. A single lapse in guard integrity can quickly escalate into a life-threatening situation, especially when machinery is in continuous use.
Chemical and respiratory hazards also pose serious risks in many manufacturing settings. Particularly in subsectors such as pharmaceuticals, electronics and chemical processing, workers often handle volatile substances or operate in environments where airborne
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contamination is a daily risk. While personal protective equipment (PPE) is essential, it is not always sufficient when dealing with odourless, colourless gases or fine particulates that can accumulate undetected in enclosed spaces. Without constant monitoring, harmful exposure can occur long before symptoms appear.
Electrical hazards also remain a significant threat, due to the number of risks associated with high-voltage machinery. Workers often carry out maintenance or operate near live electrical systems, where even a minor fault or unnoticed degradation in insulation can lead to catastrophic consequences. Additionally, as manufacturing lines become more power-intensive and interconnected, the margin for error continues to shrink.
THE ROLE OF SENSORS
In the wake of Industry 4.0, industrial sensors have become commonplace, enabling automation and real-time monitoring for higher efficiency in factories. However, sensors bring another significant benefit to industry: improved safety. By delivering real-time insights into operating conditions, sensors provide a crucial first line of defence against a range of hazards.
For example, environmental sensors can provide continuous monitoring of air quality, detecting leaks of toxic gases such as ammonia, methane or carbon
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