In recent years, the manufacturing industry has seen an increase in injuries and illnesses among workers. In fact, according to the Bureau of Labor Statistics, there were over 2.8 million cases of workplace illnesses and injuries in 2022, alone, in the private industry sector. Technology has revolutionized manufacturing safety to combat these alarming statistics by developing smart personal protective equipment (PPE) that integrates protective features into onsite gears. 

Let’s dive into what exactly PPE entails, the common issues that manufacturing industries face, and how using smart PPE can help alleviate these issues. 

What is Smart PPE?

PPE, or personal protective equipment, is worn to shield workers from hazardous conditions and prevent illnesses. This gear could include hard hats, goggles, vests, and even full-body suits. Smart PPE takes this a step further by including advanced technology in these safety types of equipment that help stop accidents from occurring. 

This type of equipment will be the future of manufacturing safety. This is due to its unique ability to use technology to forecast and prevent hazardous scenarios, which is an excellent addition to the current safety measures most manufacturing companies have in place. 

How Important is Enhancing Workplace Safety?

Ensuring workplace safety should be a top priority across all industries. From preventing horrific incidents, to fostering a healthy working environment, numerous protective measures can have tremendous benefits for everyone involved.

For example, the paint and coatings industry must enhance the workers' safety since they deal with many risky chemicals daily, which makes this environment the best place to integrate these tools. Utilizing wearable air quality sensors embedded in the gear, and keeping track of other health conditions is essential to the worker's health. So that if a problem were to occur, the smart PPE could notify the employees and provide real-time alerts. 

How Has Technology Improved Safety Hazards and PPE Assessments?

Smart PPE has greatly improved protection notifications and PPE assessments in the manufacturing industry. Let's take a closer look at some examples of how this technology has contributed to the upgrades:

  • Real-time monitoring: With the advancement of sensors and wearable devices, smart PPE can now immediately monitor workers' vitals and fatigue levels. This allows for early detection and prevention of potential accidents caused by exhaustion or overexertion.
  • Augmented reality (AR): AR devices allow employees to visualize safety issues and potential environmental risks, increasing awareness and reducing the chance of human error. For instance, in a manufacturing facility with heavy machinery, AR can share warning signs on equipment that pose a threat. 
  • Environmental sensors: Smart PPE can also come equipped with environmental sensors that detect and measure exposure to dangerous chemicals or gasses. Companies can use the information extracted to improve their workplace and lower the risks of injuries. 
  • Data collection and analysis: This innovative technology has the capability to collect data on worker behaviors, which could provide valuable insights for safety assessments. This can then lead to more targeted training and helpful intervention measures that will help address potential dangers.

Introducing these advancements in the workplace will improve employees' overall security and increase their productivity and efficiency. 

Common Safety Hazards in Manufacturing and How Innovative PPE Can Address Them

Innovative PPE has been designed to target specific safety hazards in manufacturing, including the following:

  • Human error: By using AR technology, workers can receive visual cues that remind them to perform specific welfare protocols. This can also lessen accidents, such as forgetting to turn off a machine or not following proper procedures.
  • Machine guarding: Smart PPE can monitor and alert individuals when they are close to dangerous machinery and help prevent potential traumatic experiences. In some cases, smart PPE can even automatically stop machines if a person is in danger. 
  • Vehicle collisions: In large manufacturing facilities, employees may need to operate vehicles and machinery close to each other, which could increase collisions. Companies can use sensors and GPS technology to detect nearby vehicles and alert workers, reducing the chances of accidents.
  • Slips, trips, and falls: Due to the danger of accidents such as slips, trips and falls, manufacturers should be equipped with fall detection technology that will automatically alert nearby workers or supervisors in the event of a fall, which can significantly lessen response time and potentially save lives. 
  • Electrical and chemical burns: Sensors embedded in smart PPE can alert personnel when their protective equipment is rendered ineffective in the face of hazardous substances or high levels of electricity. In the grand scheme of things, these sensors help employees avoid intense burns that require immediate medical attention. Some smart gloves are also designed to provide insulation and protection against chemical exposure.

These are just a few examples of the dangers that this tool could address for various companies. With continuous development, these new advancements can provide more secure features and lower risks in other unsafe areas as well. 

The Future of Smart PPE and Manufacturing Safety

As technology continues to grow, the possibilities for improving manufacturing safety are endless. Some future developments to look out for could include:

  • Biometric sensors that can detect physical stress and fatigue levels. This new feature will allow for more targeted interventions to prevent accidents caused by exhaustion.
  • Artificial intelligence (AI) in smart PPE will allow for real-time analysis and prediction of potential hazards in a busy working environment. 
  • IoT (Internet of Things) will enable smart PPE to assist in communicating with other devices and systems in the workplace, creating a more comprehensive and interconnected safety network.
  • The use of virtual reality (VR) devices to simulate hazardous scenarios. It could also help to train workers on proper protection protocols without putting them in dangerous situations. 
  • Sustainable technology in smart PPE will use eco-friendly materials such as biodegradable plastics and renewable energy sources.

There are still plenty of opportunities to expand the capabilities of smart PPE and further improve the workplace. So, while technology has already made significant strides in enhancing safety hazards and PPE assessments, there is still potential for even more significant improvements in the future. Let's continue exploring innovative solutions to create a safer and more efficient manufacturing industry that could benefit both employees and employers.