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Effective Loss Prevention in Manufacturing

Effective Loss Prevention in Manufacturing

In the manufacturing industry, effective loss prevention is critical for reducing accidents, minimizing risks, and ensuring smooth operations. One of the most practical and straightforward strategies is the implementation of locks. Here’s a simple guide to understanding and applying locks and other key loss prevention techniques in your manufacturing facility.


1. Enforce Lockout/Tagout (LOTO) Procedures

LOTO procedures are essential for preventing accidental machinery start-ups during maintenance. Each piece of equipment should have a specific LOTO procedure that is strictly enforced.

Best Practices:

  • Specific Procedures: Create detailed, machine-specific LOTO procedures and place them near the machinery.
  • Annual Observations: Ensure a second qualified person observes the LOTO application annually.
  • Strict Enforcement: Rigorously enforce LOTO procedures to prevent injuries and avoid OSHA citations.

2. Choose Safe Powered Material Handling Equipment

Selecting the right powered material handling equipment with built-in safety features can significantly reduce workplace injuries.

Key Considerations:

  • Modern Safety Features: Choose equipment with features like blue lights for visibility, speed governors, backup alarms, and impact monitors.
  • Operator Monitoring: Use card key systems to track who is operating the equipment and when.
  • Appropriate Equipment: Select equipment based on your facility’s layout, such as center-riding pallet jacks to prevent ankle injuries.

3. Maintain Safe Flooring and Housekeeping Practices

Slips, trips, and falls are common in manufacturing but can be minimized with proper flooring, housekeeping, and footwear programs.


  • Regular Maintenance: Implement degreasing schedules and use suitable cleaning products for your flooring type.
  • Non-slip Solutions: Apply custom floor treatments that add a grit layer to frequently wet areas.
  • Footwear Programs: Introduce non-slip footwear programs and monitor tread depth.
  • Adequate Lighting and Uniformity: Ensure good lighting and uniform steps to prevent accidents.

4. Implement Automation

Automation can reduce ergonomic injuries and address workforce shortages but requires careful integration with existing processes.

Steps to Success:

  • Ergonomic Benefits: Identify tasks that can be automated to eliminate repetitive strain injuries.
  • Integration Challenges: Ensure safety measures cover both automated and manual processes.
  • Comprehensive Planning: Collaborate with your engineering team to seamlessly integrate automation.


By implementing robust Lockout/Tagout (LOTO) procedures, selecting safe powered material handling equipment, maintaining safe flooring and housekeeping practices, and integrating automation thoughtfully, manufacturers can significantly mitigate risks and enhance operational stability. Each strategy, from the enforcement of specific LOTO procedures to the adoption of advanced automation technologies, plays a crucial role in creating a secure workplace. Commitment to these best practices not only protects employees but also ensures the longevity and success of manufacturing operations.



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