Safety in Manufacturing: Essential Steps to Protect People, Performance, and Profits

Safety in Manufacturing:

Essential Steps to Protect People, Performance, and Profits

Take control of workplace safety with Beckway’s complimentary one-week safety assessment. This free evaluation is designed to help private equity investors and manufacturing leaders identify and address safety risks early, protecting both workforce well-being and profitability.

In the manufacturing sector, workplace safety is a strategic priority that directly impacts the bottom line. The financial consequences of injuries can be extensive, affecting both immediate and long-term performance. Direct costs include medical expenses, workers' compensation, increased insurance premiums, and potential litigation fees, while indirect costs can stem from lost productivity, additional hiring and training, and the administrative burden of accident investigations.

Beyond direct financial losses, operational disruptions from workplace incidents bring significant additional expenses. Halts in production, equipment repairs, and quality issues caused by injuries and downtime can escalate costs and reduce profitability. As incidents increase, insurance premiums rise, and companies may lose safety incentives or discounts.

The reputational impact of poor safety practices can also be severe. Negative publicity can harm customer loyalty and strain supplier relationships, weakening the competitive edge. According to the Bureau of Labor Statistics, the manufacturing sector saw 2.8 million nonfatal workplace injuries and 340 fatalities in 2022 alone. The National Safety Council estimates that each injury costs manufacturers between $40,000 and $50,000.

Proactive safety investments are essential to mitigating these risks. Effective strategies include comprehensive employee training, regular inspections, ergonomic improvements, and thorough safety assessments. For tailored safety solutions that safeguard both workforce well-being and profitability, contact Beckway’s Operations practice lead, Toby Drummond, to schedule your free safety assessment today. Don’t wait—take action now to build a safer, stronger organization.

Recent Manufacturing Industry Case Studies

Safety Implementation for a $300M Electrical Infrastructure Manufacturer

Reorganized companywide safety roles, implemented ‘Train the Trainer’ programs, and launched comprehensive risk assessment processes, resulting in improved safety alignment, consistent training, and proactive risk mitigation across all operations.

Interim VP of Operations for a $200M Industrial Services Company

Reduced stockouts by 56%, lowered excess inventory by $2.8M, decreased weekly purchases by 42%, and improved inventory accuracy by 2.6% through data-driven SIOP and Power BI solutions.

Procurement Analytics and Dashboard for a $680M Industrial Goods Manufacturer

Achieved $1.2M in inventory savings, $384K in working capital improvements, and $1M in annual cost savings by enhancing procurement visibility and optimizing payment terms across 10,000 SKUs.

View Case Study

For more insights into how Beckway can support your business with customized solutions,

visit our website to explore our full range of services.

Featured Team Member:

Toby Drummond

With over 30 years of global experience in Lean and Six Sigma transformations, Toby Drummond is a Partner at Beckway, specializing in enterprise transformations. He has a proven track record of driving value creation through comprehensive assessments and tailored transformation strategies.

Toby’s expertise in optimizing processes and elevating operational efficiency has been instrumental in helping clients reach their full potential.

During his tenure at Beckway, Toby has delivered impactful results for numerous private equity funds, including Altamont, Atlas, Cornerstone, Hemingway, New Mountain, NewHold, Sterling Group, The Jordan Company, Top Spin, and TPG.

A few of Toby's recent projects include:

Packaging & Shipping Area Optimization for 6X Growth Capacity for a $245M Pharmaceutical Product Manufacturer
Reducing Backlog and Standardizing Operations for Improved Efficiency for a $100M Packaging Manufacturer
Operations Transformation Driving 2X Growth and 2.3X EBITDA for a $2B Food Manufacturer

Toby’s passion for operational excellence and continuous improvement is rooted in his early career experiences. As he reflects on his journey, he shares:

“Like many people, my first job was in a large manufacturing facility. I quickly realized that keeping operations running smoothly relied on countless functions and processes. At first, I didn’t think much about how everything worked together. But that changed when operations consultants arrived to introduce us to Lean Manufacturing. Suddenly, my priorities shifted, and I began to question everything we did. While the physical changes brought noticeable improvements in efficiency, the impact on our culture was equally transformative. Today, I prioritize value creation and encouraging teams to continuously challenge the status quo.”

Email: tdrummond@beckway.com

Stay Connected with Beckway

Have questions or need expert guidance? We're here to help.