In today’s industrial landscape, compliance is the minimum standard. The true differentiator? A culture of safety. During a recent conversation with Nikki Skelton, an Environmental Health and Safety (EHS) professional with more than 25 years of industry experience, we explored what it takes to not only meet safety regulations but to build a proactive, engaged, and world-class safety culture within an industrial manufacturing environment.
Skelton currently leads our safety initiatives at ProcessBarron, where she is focused on advancing the safety protocols from compliance-driven to courage-driven. Below are several key insights that manufacturing plants can apply.
Start Risk Assessments with the Right People in the Room
According to Skelton, one of the most common missteps in conducting risk assessments is isolating the process within the safety department.
“We’re the experts in regulation, but the people doing the work are the experts in the process.” Those operating the equipment need to be a part of identifying safety opportunities. A comprehensive and useful risk assessment requires a cross-functional team: safety professionals, operators, supervisors, and relevant stakeholders. Walking through each step of the standard operating procedure (SOP) and identifying potential hazards ensures that the final document becomes a true operational tool, not just a regulatory requirement.
PPE: An Essential Tool, But Never the First Line of Defense
While personal protective equipment (PPE) plays a crucial role, Skelton emphasizes it should always be the last line of defense. Whenever possible, engineering controls should eliminate or reduce exposure to hazards.
For example, instead of upgrading ear protection, ProcessBarron is exploring options to relocate noisy machinery to reduce decibel exposure at the source. Where PPE is required, functionality and comfort are vital, especially in environments with high heat and humidity. Selecting the right gear often requires multiple trials and direct feedback from the team.
Safety Training is Not Just for Operators
Another common gap Skelton observes is the misconception that safety training should focus solely on frontline or production workers.
“Everyone needs safety training. That includes office employees, administrative staff, and leadership.”
Proper training ensures all employees understand not only physical risks, but also ergonomic, fire, and situational hazards. For operators of heavy machinery, like cranes and forklifts, OSHA requires 36 hours of supervised, hands-on training. While simulators are a great enhancement, they are not a substitute for real-world experience.
Lockout/Tagout: The Most Life-Saving Regulation
Skelton is firm in her stance: “Of all OSHA regulations, lockout/tagout has likely saved the most lives.” By controlling hazardous energy during maintenance, organizations prevent incidents where machines could be mistakenly re-energized with workers still inside. At ProcessBarron, adherence to lockout/tagout procedures is non-negotiable.
Emergency Preparedness Requires Practice
Emergency protocols are only effective if they are understood and rehearsed. Skelton leads quarterly drills, covering everything from evacuations and severe weather to active shooter scenarios.
“We don’t just write a plan, we test it, we revise it, and we train on it again.” She recommends at minimum one drill per year per scenario, but prefers a quarterly training to keep safety procedures top of mind.
Effective Machine Guarding Requires Perspective
Proper guarding is another important safeguard, but it’s not one-size-fits-all. Assessments must account for who is using the equipment and how.
“What’s safe for someone who’s 5’3″ may not be safe for someone who’s 6’3″.” In addition to physical barriers, modern safety systems are evolving with technology: pressure-sensitive mats, two-hand controls, and light curtains that disable machinery when a person enters the danger zone.
Safety Culture Starts at the Top
At ProcessBarron, our leadership team emphasizes safety first, followed by quality, and then production. This top-down approach has led the company to impressive milestones, including over 730 days without a lost-time incident. Skelton is a proponent of accountability through behavior-based safety modeling. “Safety must lead every conversation, from executive meetings to daily team huddles.”
Empowering Employees to Speak Up
Building a courageous safety culture means encouraging employees to identify and report hazards without fear. “I tell my team: If someone speaks up about a risk, that’s not a problem, that’s a win.”
We’ve adopted a “Good Catch” program, which celebrates proactive safety behavior by publicly recognizing team members who spot and report issues. Skelton also walks the floor weekly in “OSHA inspector mode,” focusing on small details that can often be overlooked but are essential for compliance.
The Hidden Pillars of Safety Protocols
Regular preventive maintenance is critical not just for keeping equipment running smoothly, but for ensuring employee safety. Skelton shared examples from past roles (not at ProcessBarron) where poor maintenance led to machinery parts breaking loose, creating serious, even life-threatening hazards.
Equally important is ensuring communication with those performing the work. “Talk to your people,” she says. “They know where the real risks are, and they often have the best ideas for solving them.”
The Gold Standard for Safety in Manufacturing
Safety isn’t owned by one department; it’s owned by the entire team. Ready to adopt a safety culture? Manufacturers can transition from basic compliance to industry-leading safety standards and set the tone by investing in training, engaging employees in decision-making, and empowering leadership.
ProcessBarron continues to set the bar in safety-first compliance and regulations standards, thanks to our incredible team. Talk with us today about preventive maintenance options for your facility.
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