1. Shop Management and
Maintenance including Safety
GFD 1
CHAPTER 1
JESY V. DOMINGO
INSTRUCTOR

2. An efficient workshop can be one of the most cost-effective ways of maintaining plant and equipment
on site. It can also be an area of great risk. The number of potential hazards in a workshop will vary on
the size and complexity of activities carried out however there are a number of general issues that
should be continuously monitored.
SAFETY STANDARDS AND
PROCEDURES IN THE
WORKSHOP

3. Workshops should:

4. · be well lit;
· be adequately ventilated and where necessary have local exhaust ventilation;
· have a good standard of housekeeping;
· be provided with adequate fire-fighting equipment;
· only contain flammable material necessary for the day to day operation of the workshop;
· only have portable tools that normally operate at 110 volts;

5. · have clearly identified pedestrian routes and, where possible, reversing of mobile plant
should be avoided;
· be adequately
have pits that are covered when not in use or have guard rails in place;
entilated and where necessary have local exhaust ventilation;
· have a · have an inspection scheme for all tools and equipment so that they are safe to
use;
good standard of housekeeping;
· be provided with adequate fire-fighting equipment;
· have access to workstations restricted to maintenance personnel;
· only contain flammable mat· have gas bottles racked and gas welding bottles should be
fitted with a flashback arrestor;
erial necessary for the day to day operation of the workshop;
·· control the use of naked flames;

6. · have adequate sanitary and hygienic washing facilities;
· have procedures for waste management of used oils, tyres, batteries, brake and clutch
linings etc

7. The apparel industry is a labour-intensive industry. In an existing garment factory or in a new set-up
workers’ health and safety must be considered in the first place. Workers are the main resources
that keep the machine running in a factory, and making the desired products. In an unhealthy
workplace, workers could not work for a long time. All companies must follow health and safety
policies.
In a garment unit, you need to take care of the following points at the factory level.

8. · First aid box · Maintain
accident resister
· Fire extinguishers
with marked area
· Emergency lights
on the floor and in
the path to the exit
Fire alarm
· No obstruction in
the aisles on the
shop floor
· Shop layout and
evacuation plans
· Yellow lines on
the shop floor to
demarcate a
pedestrian
pathway and
space for
machines
· Exit doors
should be
kept open
while the
factory is
working
· Exit signs
· No cables left loose or visibly hanging · Enough light to the shop floor

9. · Broken needle
record policy
Canteen for
workers
· Enough toilets
for workers and
members of staff
· Safety measures
followed at every
workstation
· Adequate pure
drinking water
supply
· Encourage
workers to use
safety masks
where needed

10. Department wise safety measures:
Following are few examples of work safety that must be followed in the shop floor.

11. · Don’t keep fabric roll on the floor.
Store fabrics on the racks or on
pallets
· Keep enough space for walking and
fabric and other item movement
· Must have air ventilation and
enough light.
Fabric
Store
· Wear metal hand gloves while
operating cutting machine
· Don’t use loose wire. All power
supply must be covered
· Wear mask
Cutting
Section
· Use Needle guard while operating
on a sewing machine
· Keep walking space free of obstacle
· Wear mask in the sewing floor
· Keep enough space at each sewing
workstation for operator movement
· Provide height-adjustable chair to
workers
· Enough light
Stitching
floor
· Wear a mask while working on a
chemical process
· Keep steam pipelines insulated
Finishing
section

12. Shop personnel
organization-their
duties and
responsibilities

13. CHAIRMAN
MANAGING
DIRECTOR
EXECUTIVE DIRECTOR
GENERAL MANAGER
DEPARTMENTAL MANAGER
ASSISTANT MANAGER
APPAREL COMPANY HIERARCHY
OPERATORS AND WORKERS

14. CHAIRMAN
Chairman
The chairman of an apparel company holds the topmost position of
power and administration in such an organization and owns the
company. He/she is responsible for the initial set up and hiring of
other employees of the company. The chairman is also the president
of the board.

15. MANAGING
DIRECTOR
Managing Director
After the position of the chairman comes the next highest
most position in an apparel company and that is the managing
director or MD. The managing director is the head of the
managerial aspects of the business and works closely through
all the operations and functions of the company. All the
managers and administrators of the company may report to
the MD.

16. EXECUTIVE DIRECTOR
Executive Director
The Executive director reports to the MD and is the person who
heads all the departments including finance, accountancy, sales,
manufacturing and marketing. He/she looks after the execution of
the plans and projects.

17. GENERAL MANAGER
General Manager
The general manager heads the production and quality of the
apparel company and each of the departments may have their own
general managers. General Managers take care of the day to day
administration o

18. DEPARTMENTAL MANAGER
Departmental Manager
Each department is headed by the departmental manager who
makes sure that the tasks in his/her department are running
smoothly and are well coordinated with that of other departments.

19. ASSISTANT MANAGER
Assistant Manager
Assistant managers work under general or departmental managers
and take their orders to execute daily tasks without glitches and
errors. They help all the employees of the department in reaching
their particular goals.

20. Operators and Workers
Each department is made up of a number of operators and workers
who are skilled professionals who carry out tasks such as designing,
stitching, running machines, running sales, performing marketing
tasks, doing accountancy and handling finances. These are the
professionals who form the backbone of the organization.
OPERATORS AND WORKERS

21. A garment factory is a place where complete garments
are made from the fabrics following a chain of processes.
A process flowchart will give a better idea of how things
are done in a garment factory. As mentioned in the title,
this article will show you the different departments of a
garment factory. Departments are set-up based on the
group of activities to be performed by a team of people.
Further, we will see the various functions of the different
departments of a garment unit. Garment manufacturing
is a complex process that starts with sample
development and end after shipping the finished
garments to the buyers.
Different
Departments in a
Garment Factory
and Their
Functions

22. Here is the list of garment factory
departments. These departments include
the pre-production departments,
production, and post-production
departments. The supporting departments
are also listed here.
Different
departments of a
garment factory

23. Problem Solution Unique Value
Proposition
Unfair Advantage Customer Segments
Existing
Alternatives Key Metrics
High Level
Concept Channels
Early Adopters
Cost Structure Revenue Streams

24. Machine
Maintenance
department
Garment Washing
department
Finishing
department
Printing
department
Embroidery
department
Supporting departments in a garment factory

25. In the previous slides pre-production and
production departments are listed. To run the
factory smoothly, with production departments,
one needs to set up some auxiliary
departments. Some of the supporting
departments of a garment manufacturing setup
are as followings

26. · Industrial
Engineering
Department
· EDP / IT
department
· Accounting
Department
· Human
Resource and
Administration
· Shipping and
documentation

27. Activities of different departments explained here are followed by garment
export houses as well as domestic garment manufacturers. You can define the
job profile of your employees based on these and if required you modify the
same.
Various functions and activities
of different departments in a
garment factory

28. The marketing department in a garment company is responsible for
marketing products made by the factory, finding new customers, and
bringing more and more orders for the company. A marketing department
is headed by the marketing manager and supported marketing team.
MARKETING
DEPARTMENT

29. · They meet with prospects and existing buyers. They show their latest product development (designs) to the
buyer. They are given responsibility for business development for the company.
· This department showcases factory’s ability for developing new designs, factory compliance, and quality
policy and quality performance.
· The most common marketplace for manufacturers is international apparel shows and exhibitions, where
buyers and sellers meet to find each other. In the exhibition, buyers pick their interesting design and place
orders if their target price is met.
· In this internet age, garment factories build websites for marketing purpose and increase their visibility to
potential customers. Small factories post their product in online yellow pages and do content marketing to
reach a bigger market. Social Media like Facebook, LinkedIn and Twitter are used as marketing tools.
· More than just developing new clients, retaining existing customer is also important. To retain your existing
customers, you need to satisfy your customers by shipping quality products and timely delivery and providing
quality services. The main mantra to retain customers and making them marketer for you is to deliver more
than you are paid for. Deliver more than commitment and customer expectations.
MARKETING DEPARTMENT

30. · Apparel design department is responsible for product development. They focus on developing garment
designs in similar product categories the company does its business. Designers develop new design collection
every season. Designers make designs as per the latest trends and buyers test. For big manufacturers, the
designing department plays an important role in retaining customers by showing new designs to their buyers in
every season.
· Designers develop a library for fabrics, trims and accessories, and for garments.
· Apparel retailers and brands those have own manufacturing set-up, normally set up the design department for
developing new designs.
DESIGN DEPARTMENT
ACTIVITIES

31. ·Merchandising department works as a mediator in between factory and buyers. This
department is considered as the heart and soul of the company. They coordinate with
buyers for orders, send garment samples for buyer approval and receive comments on
samples and other approvals. Merchandiser prepares the bill of materials, prepares
garment costing sheet and follows up of production activities.
MERCHANDISING
DEPARTMENT

32. · Communicate with buyers
· Review the garment sample
· Develop garment sample
· Product costing
· Develop good relationship with customers
· Scheduling of pre-production and production activities
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33. · Preparing Bill of Material (BOM) and fabric indent
· Source raw materials
· Provide quality approval
Prepare Production File
Conduct Pre-Production Meeting
· Execute orders
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34. · Providing after sales services
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35. · Pattern Making
· Pattern Grading
· Sample Development
· Garment FIT checking and correction of patterns
· Incorporate buyer’s comments on samples
· Making production viable sample
· Fabric Consumption Calculation
· Marker planning
·Pattern making department makes garment patterns and digitize patterns to CAD. CAD stands for Computer
Aided Design. Pattern making department is headed by Pattern master. Pattern making department is also
known as the technical department.
Following are the major Activities of Pattern Making Department
PATTERN MAKING
DEPARTMENT

36. Sampling department makes all kind of samples that need to be submitted to the buyer. Sampling department checks
fit of the sample. Sampling department communicates problems related to orders to the production department.
As mentioned in the above that in small size factories, pattern making, and sampling is kept in one department. They
have common activities. Sampling department’s activities are
· Reading garment spec and understanding workmanship of the garment.
· Assisting merchants in preparing bill of material for the sample
· Calculating fabric consumption
· Making garment samples by following complete processes of cutting, sewing, finishing and checking.
· Measurement all samples and check the quality of the garment samples. Prepare quality inspection report for
measurement and visuals.
· Fabric shrinkage test is done in garment form.
· Coordinate with production team about communicate about critical points for stitching and handling of a style
SAMPLING DEPARTMENT

37. The fabric store is handled by Fabric in-charge and the in-charge is assisted by a team of helpers for loading
and unloading fabrics and issuing fabric to cutting department. Fabric department receives and stores all kind
of fabrics. Fabric rolls are kept in the rack or on wooden pallets.
Following are the major Activities of the fabric store:
· Sourcing of Fabrics
· Receive Raw Materials
· Checking of Greige and Finished fabric
· Prepare shade band for dyed and printed fabrics
· Basic Testing of Physical properties of fabrics
· Maintain inventory record for fabrics
· Fabric Issue
· Fabric printing
· Fabric Reconciliation
· Communication with Fabric supplier
FABRIC STORE AND FABRIC
SOURCING DEPARTMENT

38. Like fabric store, this store receives all kind of trims and accessories and store in racks. Small size factories,
fabric and trim store are headed by the same person. And the functions of this department includes followings.
· Sourcing trims like sewing thread and packing accessories
· Checking of Trims and accessories in term of quality and quantity
· Storing trims and inventory maintenance
· Trim and accessory issue
· Dying of trims like twill tape
· Arranging trims in racks or bin to get trims easily when the request received from someone.
TRIMS AND ACCESSORY
STORE

39. Factories those have separate PPC department, following activities are carried out by them.
· Job or Task Scheduling
· Material Requirement Planning (Inventory)
· Loading Production
· Process selection & planning
· Facility location
· Estimating quantity and costs of production
· Capacity planning
· Line planning
· Production follow up and execution
· Learn more about PPC in the apparel industry by reading my book on this subject.
PRODUCTION PLANNING
AND CONTROL DEPARTMENT

40. This department is responsible for cutting of fabrics and feeding sewing department
with cuttings. Cutting department’s capacity is planned as per daily feeding
requirement to the sewing lines. Cutting department set up with cutting department
head, cutters, spreaders, quality checkers, and helpers for sorting, ply numbering and
bundling.
CUTTING DEPARTMENT
ACTIVITIES

41. List of activities of the cutting department is as follows:
· Fabric receiving from the fabric store
· Fabric relaxation
· Cut planning
· Fabric spreading/layering on the cutting table
· Marker Planning
· Marker making
· Cutting of fabrics
· Sorting, Bundling and numbering of garment plies (parts)
· Inspection of cut components
· Sorting of printed and embroidery panels
· Re-cutting of panels
· Fusing Garment Components
CUTTING DEPARTMENT
ACTIVITIES

42. Main jobs of the sewing department are stitching of garment. In the sewing floor, various
types of production systems and line layout are used. Factories either work in an assembly
line or group system. Major tasks of this department are as follows but not limited to these
only.
· Line setting
· Garment stitching
· Marking parts
· Ironing garment components
· Checking of stitched garments
· Stitching Alteration
· Documentation
SEWING DEPARTMENT

43. This department repair machines and look after maintenance of sewing machines. Major activities of the
machine maintenance department are
· Machine set up
· Repairing sewing machines
· Maintaining inventory of machine parts
· Doing preventive maintenance for machines and equipment
MACHINE MAINTENANCE
DEPARTMENT

44. Industrial Engineering department assists production department in setting line,
improving production and measuring production performance. Major activities of
Industrial Engineering department are product analysis, making operation bulletin,
calculating garment SAM, making line layout and workstation layout. They capture
production data and prepare daily production report.
INDUSTRIAL ENGINEERING
DEPARTMENT

45. In a typical garment unit, industrial engineering department handles following activities
· Estimating the SAM of the garment for a new style for costing
· Calculating thread consumption for garments
· Providing operational breakdown with SAM and target for each operation for an order (style)
· Selection of machines and work-aids and number of machines for each operation of a
particular order
· Method improvements through method study
· Time study of the operators
· Capacity Study of operators
· Line Balancing
· Calculating direct labor cost
· Develop detailed production methods, from detailed manual movements to major decisions on
technology.
· Documentation of all methods using manuals, computer-based system as appropriate.
· Operator performance improvement
· Operator training program
· Production Control system

46. Sometimes garments need to be washing after stitching to remove dust,
tracing mark and to give a washed look to the garment. This department
washes the garments, cut panels (if required), wash garment samples as
required.
WASHING DEPARTMENT

47. Stitched garments are finished prior to packing into poly bag. Major activities of a finishing department
include thread trimming, checking of garments and ironing. Packing department in a factory works side
by side of the finishing department. Folding, tagging and packing of garments are done in the finishing
department. Based on product categories finishing room activities may vary.
Activities of the finishing department are listed below
· Thread trimming
· Attach button and button holing in case these jobs are done in the stitching section
· Checking of garments
· Stain removing
· Garment Pressing / Ironing
· Folding and Tagging
· Packing
· Communicate with internal department
FINISHING DEPARTMENT

48. Responsibilities of the quality control department may vary organization to organization but main
activities almost remain the same. Activities of the Quality control department are as follows.
· Setting up Quality Standards
· Establishing Quality SOP
· Quality Assurance
· Quality Control activities at the Pre-production stage:
· Auditing inward fabric and trims and ensuring only quality goods are accepted.
· Involvement in product development and sampling stage and take care of quality aspects of
samples.
· Ensure that no faulty fabric is sent for cutting. If a minor fault is present in the fabric, defects
should be marked on the fabric and the same thing must be communicated to the cutting
department.
· Preparing the audit report of the fabric and trims quality.
· Conducting pre-production meeting before production start.
QUALITY CONTROL / QUALITY
ASSURANCE DEPARTMENT

49. Departments if a garment factory those are no
directly involved in garment production but
support garment production team to perform
their work smoothly. Necessary supporting
departments are Accounting, EDP, Shipping and
documentation, Human resource and
Administration.
Supporting
departments and
their activities

50. · Accounting department prepare payroll for employees, give payments to
workers and write checks for staffs. They manage accounts of the company.
· Maintain records of supplier payment and follow up with buyers for pending
payment. This department is involved in all kind payment and cash
management.
ACCOUNTS DEPARTMENT
ACTIVITIES

51. · This department is concern about the social issue of the employee. They look
after recruiting and employee welfare.
· This department maintains employee attendance and absent records.
· Handle labour issues
· Factory compliance and social compliance
· New employee orientation
HUMAN RESOURCE AND
ADMINISTRATION

52. Garment factories use many electronics items such as computers, printer, Barcode systems etc.
Computers are used for daily activities like mailing, making reports and accounting software, EPRs
etc. An EDP department is necessary for troubleshooting of the computers and software.
The major activities of this department are
· Purchasing electronic items
· Breakdown maintenance of computers and other hardware
· Supporting internet and mailing activities
· Protecting the company’s server from outside bugs and viruses
· Database maintenance
· Report generating
ELECTRONIC DATA
PROCESSING (EDP)

53. Shipping and documentation department prepare shipment related documents. They communicate
with buyers for shipment dispatch and send the shipment to buyers.
SHIPPING AND
DOCUMENTATION

54. GOOD WORK HABITS
AND SAFETY
PRACTICES IN THE
SHOP

55. BE
PRODUCTIVE,
HAVE
JOB
SATISFACTION,
AND
GET
ALONG
WITH
YOUR
BOSS
AND
COWORKERS
Good work habits are essential for anyone who wants to succeed in his
or her job, whether it is an after school or summer job or one that is a
step on the career ladder. They increase your productivity and job
satisfaction and help you have better relationships with your boss and
coworkers. We asked experienced professionals and parents what good
work habits they would tell young adults they must have. Here is their
advice:
Good Work Habits for a
Successful Career

56. Your boss's feedback is valuable. He isn't necessarily criticizing your performance
because he dislikes you. He may be trying to help you succeed.
Take Criticism Well
Don't contribute to the gossip mill and remain neutral if your coworker tries to pull you
into it or talks behind another colleague's back.
If you have a complaint about something, always have ideas about how to make it
better. When you turn negativity into positive action, you will sound professional
instead of whiny.
Always go to work when you are scheduled to be there. Only call out if you are truly
sick.
If your boss asks you to come into work when you are not scheduled, be willing to
make every effort to go. You should also be cheerful about it (or pretend to be).
Always build a buffer into commuting time, as well as your timeline for working on a
project.
Don't Gossip
Be a Problem Solver,
Not a Complainer
Be Dependable
Be Willing to Go Into
Work If Your Boss Asks
Allow Extra Time
for Everything

57. You certainly won't know everything when you first start out, and you will still have
more to learn even as you move up in your career.
Be Prepared to Not Know
Everything
Texts and notifications that pop up on your cell phone can be a big distraction while
you are working. Check your phone only during breaks.
Dressing for the position you want lets your employer visualize you in that job.
No one, no matter how talented, can do it all alone. If you need assistance, don't be
afraid to ask for it. Realize others may require it too but may hesitate to ask, so offer a
hand when you can.
When your boss assigns a task, perform it to the best of your ability.
There is nothing to be gained by not being nice to others. When you are kind, it will make others happy, and
they will have goodwill toward you. Be especially kind to those who seem the most miserable. They may
really need it and it could have a positive effect on them.
Put Your Phone Away
While at Work
Dress for a Better
Job
Ask for Help and
Offer It as Well
Always Do Your Best
Be Kind

58. While doing more than your boss or customers expect may get you recognition, more
importantly, it will give you experience and personal satisfaction.
Do More Than Is Required and Do
It With a Smile and a Positive
Attitude
Be ready to pitch in when you are needed. It may involve doing something that isn't in
your job description, but you will demonstrate that you are flexible
When problems arise, solving them gives you the chance to showcase your strengths and
sharpen your skills.
Beware of extensively talking about your personal problems. What you tell your coworkers
could influence their perception—and your boss's—about your ability to do your job and it
could make you the subject of workplace gossip.
If you don't understand how to do something, or how something works, get clarification.
You may feel foolish asking what you consider a silly question, but that is much better than
making an avoidable mistake.
It may take a little longer to look over your work, but it is much better to catch your errors
before someone else does.
Never Say "It's Not
My Job"
Look at Problems as
Opportunities, Not Challenges
Keep Personal Problems
Out of the Workplace
Ask Questions
Always Proofread
Your Work

59. While it is important to like what you do, you will be terribly disappointed if you expect your
job to be fun and games all the time. There are things you will need to do that won't be
glamorous, but as they say, "that's why they're paying you the big bucks."
Don't Forget That Work Is Work
If you don't know what they are, get the facts from someone whose job it is to know them,
for example, the human resources department. If you ask a coworker instead, he or she
may give you the wrong answer, and you will bear the consequences.
If someone asks you a question and you truly don't know the answer, rather than giving
out misinformation, be honest. Say you aren't sure, but you will find out. Then do it.
It is impossible to do good work if you are disorganized.
Arrive at work early and get ready for the day by anticipating what you will have to do while
you are there. Do not get flustered by last minute changes. You may have to modify your
plans.
Delegate tasks if you have the authority to do so but don't expect anyone to do your dirty
work for you.
Make Sure You Understand
Company Policies
Don't Be Afraid to Say "I
Don't Know"
Be ​
Organized
Prepare for Your Day
Never Ask a Subordinate or
Colleague to Do Something
You Would Not Do

60. Smiling makes you feel better and it makes others feel better. Of course, don't smile when
it is inappropriate to do so, for example when something tragic happens.
Smile, and When Things Are at
Their Worst, Smile More
When someone is talking, listen carefully. Don't think about how you are going to respond,
but instead, try to absorb what the person is telling you. You can ask questions later
Putting off doing your work, even a project you dread, won't make it go away. You might as
well get it over with.
Listen to Understand, Not
React
Stop ​
Procrastinating

61. “Safety should be a habit.” It’s an
admirable idea, and it’s frequently
stated as a goal. But what does it really
mean? In this article we'll look at good
safety habits in the workplace: what
they are, why they’re important and
how they come about, and providing
strategies to build safe work habits on
the job. But let’s start with some basic
questions.
Safety Habits
and the Benefits
They Bring

62. Practicing safety is all about understanding hazards and mitigating risks. Looking from
the top down, OSHA standards can guide safety managers who remedy problems and
develop safe processes. And from the bottom up, good habits can help workers act
safely, almost automatically. Ultimately, both approaches are critical.
The “top down” part is where safety professionals have the most power, creating systems
and implementing engineering controls to mitigate hazards. But the “bottom up” part is
where the rubber really hits the road. Established systems and procedures can’t do much
good if people don’t understand and respect them.
Safety habits are an important way to gauge the health of what’s happening on the
ground—the “bottom up” perspective. When you see the right habits, it’s a sign that
people are following the rules all the time, rather than only doing the right thing when
someone’s watching. Good safety practices begin with good habits.
How Can You Practice
Safety at Work?

63. A habit is a decision you never even think about; it’s a choice you’ve
already made.4 You don’t need to decide whether or not to brush your
teeth before bed each night, for example—you decided that long ago.
When workplace safety is a habit, it follows the same pattern: basic
everyday precautions, like wearing PPE, become automatic.
You can also think of habits as mental shortcuts. They allow people to
navigate the constant flow of everyday life and all the small choices that
are part of it, while conserving mental energy for the most important
decisions.
That’s why it’s so critical to promote good safety habits. Researchers
have found that habits account for as much as 40% of human behavior.3
Habits guide our most routine, unthinking behaviors, and good habits will
guide them in good directions.
Why Do Habits Matter?

64. ARepetition is the key to building a strong habit. Research shows that a new habit takes at
least 21 days to take hold, but the average worker will require ten weeks of conscious
repetition before the action becomes automatic, and the most forgetful members of the
team will take almost twice as long.3
Consistency is also vital for habit formation. In the early stages of developing a habit, even
momentary lapses can erode the behavior—if a worker ducks onto the production floor to
run an errand without a hardhat “just this once,” then skipping PPE becomes a possibility
in their mind. To build firm habits, you need to enforce adherence without exception,
especially in the early days of development.
So instead of focusing on punishment for workers who forget to follow procedure, take a
moment to proactively reinforce positive behavior as it’s happening. A timely nudge can
preemptively ensure compliance, doing far more to form the habit than any amount of
post-lapse punishment.
How Do You Encourage Good
Safety Habits in the Workplace?

65. Maintaining a system of cues and rewards after the formation period
will help keep the habit firmly entrenched and help spread it among
new hires. The same proactive approach that seeded the habit will
help sustain it, and an incentive system that rewards consistency will
complete the feedback loop that maintains the ingrained behavior.
Celebrating milestones will encourage the workforce to keep the
streak going.
How Can You Keep Good
Habits Going?

66. SHOP
SAFETY

67. Everyone must wear
safety glasses in a
shop environment.
Even when you're not
working on a machine,
you must wear safety
glasses. A chip from a
machine someone else
is working on could fly
into your eye.
if you have long
hair or a long
beard, tie it up
If your hair is caught in
spinning machinery, it will be
pulled out if you're lucky. If
you're unlucky, you will be
pulled into the machine.
No loose clothing
Ties, scarves, loose
sleeves, etc. are
prohibited.
No gloves Remove jewelry
Be aware of what's
going on around
you
For example, be careful
not to bump into someone
while they're cutting with
any type of saw.
Wear appropriate
shoes
No open-toed sandals.
Wear shoes that give a
sure footing. If you are
working with heavy
objects, steel toes are
recommended.
Early Adopters
What are the specific
characteristics of your
early adopters?
Don't hurry
If you catch yourself rushing, slow down. Don't rush speeds and feeds. You'll
end up damaging your part, the tools, possibly the machine itself, and maybe
yourself.
Listen to the machine
If something doesn't sound right, turn the machine off.
Concentrate on
what you're doing
If you get tired, leave.

68. Don't let someone
else talk you into
doing something
dangerous or
disabling a safety
device to do a job
faster.
It's not worth the risk.
Don't attempt to
measure a part
that's moving.
Before you start the
machine, study it.
Know which parts move,
which are stationary,
and which are sharp.
Double check that
your workpiece is
securely held.
Do NOT leave
machines running
unattended.
If you don't know
how to do
something, ASK!
Remove chuck keys
and wrenches.
Clean up machines
after you use them
A dirty machine is
unsafe and
uncomfortable to work
on.
Don't Do not use compressed air to blow machines clean
This endangers people's eyes and can force dirt into machine bearings.

69. INDUSTRIAL
SAFETY

70. 1. Conduct regular workplace inspections. On a casual stroll from one side of your workplace to
another, you probably won’t notice many safety risks because you won’t be actively looking for
them. Make it a point to do a regular workplace inspection. That way, you’ll search for things
that could pose danger and spot things you’ve never seen before. A safety services expert can
also come and inspect your facility to identify risks and provide solutions.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

71. 2. Encourage employees to report any unsafe working conditions. In case there’s something you
don’t see, make sure your employees feel empowered to come forward and report equipment or
conditions that are safety risks.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

72. 3. Mandate training for new hires. When hiring people to do dangerous jobs, like operating a
forklift or working with heavy machinery, it’s important to make sure employees are trained in-
house. And, in accordance with federal and state requirements.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

73. 4. Offer ongoing safety training. When an employee is up to date on job safety, they’re
more likely to work safely. Regular safety training sessions benefit all.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

74. 5. Allow only authorized personnel to use machinery. If an employee hasn’t
been officially trained to use a certain machine, they shouldn’t be using it.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

75. 6. Provide personal protective equipment to all
employees who need it. Think: safety glasses, hard
hats, steel-toed boots, aprons, gloves, and more.
Encourage all employees to wear personal protective
equipment when and wherever necessary.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

76. 7. Hang mirrors and warning signs to combat blind spots. If
your employees are operating heavy machinery in the
workplace, help them see at all angles with corner mirrors
and blind spot signs. It’s a simple, affordable solution to
prevent larger problems.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

77. 8. Prevent slips, trips and falls. Ask employees to report or clean any
spills or leaks across the facility. Also, perform regular maintenance
on spots with worn, ripped, or damaged flooring that could cause
trips or falls.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

78. 9. Store flammable liquids away from the work area. If your
employees work with any combustible materials, keep only the
amount they need for the job nearby. Store the rest safely in
approved containers in an assigned storage area
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

79. 1O. Store all other materials in their proper places. At the
end of the workday, make sure employees clean up their
spaces and store all materials in their designated places.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

80. 11. Keep aisles and exits clear of clutter. In case of
emergency, all routes should be clear. Pay special
attention to clearing paths to stairways and fire
doors.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

81. 12. Promote a substance-free workspace. Employees who use
drugs or alcohol while on the clock can do serious damage.
Substance use can lead to injured employees or other team
members.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

82. 13. Create a safety incentive program. Where there’s a reward,
there’s motivation to earn that reward. One of the best ways to
support a safe workspace is to reward employees for maintaining
one. Offer monetary incentives, lunch gift cards, raffle entries,
assigned parking spots, or other prizes to promote a safe
workspace.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

83. 14. Ensure injuries are reported as soon as possible.
Workplace injuries and illnesses should be reported and
investigated within 24 hours, no matter how small the
incident seems. Follow proper, prompt protocol.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

84. 15. Have an emergency action plan. Do you have an
evacuation route? Do all employees know where to exit
and where to meet after? At the time of hire, ensure all
employees are briefed on these important details.
INDUSTRIAL SAFETY TIPS TO ABIDE
BY.

85. Hazards and
their
prevention
system
approach
What is a Hazard?
When we refer to hazards in relation
to occupational safety and health the
most commonly used definition is ‘A
Hazard is a potential source of harm
or adverse health effect on a person
or persons’.

86. Hazards and
their
prevention
system
approach
What is Risk?
When we refer to risk in relation to
occupational safety and health the
most commonly used definition is
‘risk is the likelihood that a person
may be harmed or suffers adverse
health effects if exposed to a hazard.

87. The level of risk is often categorised upon the potential harm or adverse health
effect that the hazard may cause, the number of times persons are exposed and
the number of persons exposed. For example exposure to airborne asbestos fibres
will always be classified as high because a single exposure may cause potentially
fatal lung disease, whereas the risk associated with using a display screen for a
short period could be considered to be very low as the potential harm or adverse
health effects are minimal.
CATEGORISING RISK

88. What are Control Measures?
Control measures include actions that
can be taken to reduce the potential
of exposure to the hazard, or the
control measure could be to remove
the hazard or to reduce the likelihood
of the risk of the exposure to that
hazard being realised. A simple
control measure would be the secure
guarding of moving parts of
machinery eliminating the potential
for contact. When we look at control
measures we often refer to the
hierarchy of control measures.

89. Elimination of the hazard is not always achievable
though it does totally remove the hazard and thereby
eliminates the risk of exposure. An example of this
would be that petrol station attendants in Ireland are
no longer exposed to the risk of chronic lead
poisoning following the removal of lead from petrol
products sold at forecourts.
Eliminate the
hazard

90. Substituting the hazard may not remove all of the
hazards associated with the process or activity and
may introduce different hazards but the overall harm
or health effects will be lessened. In laboratory
research, toluene is now often used as a substitute
for benzene. The solvent-properties of the two are
similar but toluene is less toxic and is not categorised
as a carcinogen although toluene can cause severe
neurological harm.
Substitute the
hazard with a
lesser risk

91. Isolating the hazard is achieved by restricting access
to plant and equipment or in the case of substances
locking them away under strict controls. When using
certain chemicals then a fume cupboard can isolate
the hazard from the person, similarly placing noisy
equipment in a non-accessible enclosure or room
isolates the hazard from the person(s).
Isolate the
hazard

92. Engineering Controls involve redesigning a process to
place a barrier between the person and the hazard or
remove the hazard from the person, such as
machinery guarding, proximity guarding, extraction
systems or removing the operator to a remote
location away from the hazard.
Use engineering
controls

93. Administrative controls include adopting standard
operating procedures or safe work practices or
providing appropriate training, instruction or
information to reduce the potential for harm and/or
adverse health effects to person(s). Isolation and
permit to work procedures are examples of
administrative controls.
Use
administrative
controls

94. Administrative controls include adopting standard
operating procedures or safe work practices or
providing appropriate training, instruction or
information to reduce the potential for harm and/or
adverse health effects to person(s). Isolation and
permit to work procedures are examples of
administrative controls.
Use
administrative
controls

95. Personal protective equipment (PPE) include gloves,
glasses, earmuffs, aprons, safety footwear, dust
masks which are designed to reduce exposure to the
hazard. PPE is usually seen as the last line of defence
and is usually used in conjunction with one or more of
the other control measures. An example of the
weakness of this control measure is that it is widely
recognised that single-use dust masks cannot
consistently achieve and maintain an effective
facepiece-to-face seal, and cannot be adequately fit-
tested and do not offer much, if any real protection
against small particulates and may lead to a false
sense of security and increase risk. In such instances
an extraction system with fitted respirators may be
preferable where the hazard may have significant
health effects from low levels of exposure such as
using isocyante containing chemicals.
Use personal
protective
equipment

96. Risk assessment is the process where you:
· Identify hazards,
· Analyze or evaluate the risk associated with that hazard, and
· Determine appropriate ways to eliminate or control the hazard.
WHAT IS A RISK
ASSESSMENT?

97. A general definition of adverse health effect is "any change in body function or the
structures of cells that can lead to disease or health problems".
Adverse health effects include:
· Bodily injury,
· Disease,
· Change in the way the body functions, grows, or develops,
· Effects on a developing fetus (teratogenic effects, fetotoxic effects),
· Effects on children, grandchildren, etc. (inheritable genetic effects)
· Decrease in life span,
· Change in mental condition resulting from stress, traumatic experiences, exposure to solvents, and so on, and
· Effects on the ability to accommodate additional stress.
WHAT IS AN ADVERSE
HEALTH EFFECT?

98. Not necessarily. To answer this question, you need to know:
· What hazards are present,
· How a person is exposed (route of exposure, as well as how often and how much exposure
occurred),
· What kind of effect could result from the specific exposure a person experienced,
· The risk (or likelihood) that exposure to a hazardous thing or condition would cause an injury, or
disease or some incidence causing damage, and
· How severe would the damage, injury or harm (adverse health effect) be from the exposure.
WILL EXPOSURE TO HAZARDS IN THE WORKPLACE
ALWAYS CAUSE INJURY, ILLNESS OR OTHER ADVERSE
HEALTH EFFECTS?

99. The effects can be acute, meaning that the injury or harm can occur or be felt as soon as a person
comes in contact with the hazardous agent (e.g., a splash of acid in a person's eyes).Some responses
to may be chronic (delayed). For example, exposure to poison ivy may cause red swelling on the skin
two to six hours after contact with the plant. On the other
hand, longer delays are possible: mesothelioma, a kind of cancer in the lining in the lung
cavity, can develop over 20 years or more after exposure to asbestos.
Once the hazard is removed or eliminated, the effects may be reversible or irreversible. For
example, a hazard may cause an injury that can heal completely (reversible) or result in an
untreatable disease (irreversible).
WILL EXPOSURE TO HAZARDS IN THE WORKPLACE
ALWAYS CAUSE INJURY, ILLNESS OR OTHER ADVERSE
HEALTH EFFECTS?