CASE STUDY: Increasing Visual Awareness of Signs to Ensure Relevant PPE is Worn in Specific areas

Introduction

In high-risk industrial environments, ensuring workplace safety and efficiency is paramount. A leading engine manufacturer in Wales sought to enhance its operational safety standards and improve workflow efficiency through advanced visual signage solutions. The challenge was to implement a comprehensive system that improved worker awareness, regulated high-traffic areas, and automated access control.

Company Background

The company is a well-established global manufacturer in the engineering industry, known for its commitment to innovation, safety, and operational excellence. The Wales-based facility plays a crucial role in maintaining high safety and efficiency standards while handling complex engine components. As part of its continuous improvement initiatives, the company sought a solution that would further enhance workplace safety and streamline operations.

Challenge

• Workplace Safety Risks: Insufficient signage and demarcation in high-traffic areas increased the risk of accidents and near misses, due to constant machine wear and tear on the floor markings.
• PPE Compliance: Limited visual reminders led to inconsistencies in personal protective equipment (PPE) adherence.
• Traffic Flow Management: The need for better-regulated pedestrian and vehicle movement to prevent plant-people conflicts.

Solution: Advanced Visual Safety Signage

To mitigate these risks and improve operational efficiency, the engine manufacturer implemented an advanced visual signage system. This solution included:

• PPE Protection Signage: Strategically placed LED projected visual cues to reinforce mandatory PPE compliance.
• Hatched Safety Zones: Clear demarcation of restricted and high-risk areas to enhance hazard awareness.
• Automated Roller Door Stop-and-Go Signage: Smart LED signage to control access and improve workflow efficiency.
• Custom Safety Markings: High-visibility floor markings to direct pedestrian and vehicle traffic safely.

Implementation

• Site Assessment: Comprehensive evaluation of high-risk zones and workflow bottlenecks.
• Design & Planning: Custom signage layout tailored to the facility's operational needs.
• Installation: Installation of projections, sensors, wiring, automated indicators, and PPE signage.
• Testing & Calibration: Verification of visibility and system function across varied conditions.
• Training & Awareness: Briefings for selected staff to interpret and adopt the new safety systems.

Results

Efficiency Improvements:

• Enhanced workflow and reduced congestion in operational zones.
• Automated access reduced delays at roller doors.

Safety Enhancements:

• Increased PPE compliance due to clear visual cues.
• Fewer near-miss incidents due to increased worker awareness.
• Improved pedestrian and vehicle interactions with clear safety zones.

Financial Impact:

• Lower incident-related costs from reduced safety breaches.
• Higher operational efficiency led to less downtime and higher throughput.

Conclusion

The implementation of advanced visual safety signage significantly improved safety and efficiency at the Wales-based engine manufacturer. With a tailored set of visual solutions, the company demonstrated leadership in proactive safety and operational excellence.

This project highlights how forward-thinking signage solutions can elevate industrial safety standards while driving measurable operational benefits.

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