Automation of Industrial Safety Processes

From Routine to Analytics: Why Automation Has Become a Necessity

Modern production generates colossal volumes of data in the field of occupational health and industrial safety. Processing these arrays manually inevitably leads to information loss, operational errors, and the inability to conduct prompt analysis. In her presentation, Irina Feigina, Leading Occupational Safety Specialist at Krastsvetmet OJSC, analyzes the practical experience of transitioning from paper document flow to a unified information space based on 1C: Industrial Safety.

Using her company as an example, the speaker shows how automating basic processes — from special assessment of working conditions to organizing medical examinations — frees up line managers' time for developmental tasks and reduces the risks of penalties.

Digitizing Basic Processes: From Briefings to Medical Examinations

The first stage of system implementation was the automation of routine operations. The speaker examines in detail the process of converting personal training cards into electronic format. Previously, hundreds of paper cards were stored in managers' offices, making it difficult to control the timely completion of briefings and knowledge checks. Transferring over one and a half thousand cards into the system made it possible to set up automatic notifications and ensure process transparency.

A similar approach was applied to the organization of medical examinations. The generation of electronic lists and referrals, as well as the consolidation of information on contraindications, made it possible to prevent employees from performing duties if they had medical restrictions.

Integration with Laboratory Systems: Control of Working Conditions

Special attention in the presentation is given to the automation of production control. Previously, line managers received measurement protocols with incomprehensible numbers, which required additional explanations from the occupational safety service. Integrating 1C with the Laboratory Information Management System (LIMS) allowed automating the comparison of actual results with hygienic standards (MPC, MPL).

Now the system independently analyzes the data and, upon detecting exceedances, automatically sends notifications to the responsible managers. This solution significantly increased the promptness of responding to deviations in working conditions.

Managing the Lifecycle of Personal Protective Equipment (PPE)

One of the most interesting cases presented by the speaker is a project to track the lifecycle of acid-resistant workwear. The trigger for its launch was an incident when an employee received minor burns due to using workwear with an expired operational life.

To solve the problem, the company implemented a system for marking workwear with fabric barcodes and equipped process participants (warehouse, laundry) with data collection terminals. This made it possible to track the number of washes (with a set limit of 30 cycles) and timely replace the clothing before it lost its protective properties.

Incident Registration and Risk Assessment

The speaker analyzes the process of automating the registration and investigation of incidents, including micro-injuries and near misses. The simple interface of the incident card using event type directories allows managers to quickly enter information. The system automatically calculates investigation deadlines and sends notifications to stakeholders.

Regarding risk assessment, automation made it possible to move away from cumbersome Excel spreadsheets. The system controls the assessment process (without considering measures, with existing and additional measures) and blocks the completion of the procedure if the residual risk exceeds permissible values, requiring the development of corrective actions.

Data Visualization: "Safety Pyramid"

To present work results to top management and line managers, a "Safety Pyramid" dashboard integrated with Power BI was developed. The tool visualizes both reactive and proactive indicators (days without accidents, LTIFR, number of identified risks and conducted investigations) in real time, ensuring the transparency of the industrial safety management system.

What You Will Learn from This Webinar:

• How to justify to management the need to implement an IT system in the field of occupational safety?
• How does the automation of production control simplify the work of line managers?
• How to organize the tracking of the workwear lifecycle using barcoding?
• How does the system help control the implementation of measures based on the results of incident investigations?
• How to visualize occupational safety data for top management using dashboards?