How to Use: Walk the facility from a safe distance—never touch machines or chemicals. Use a flashlight to check for dust or leaks. Ask the facility manager: “Last safety check? Training logs?” Mark High (unguarded machines, gas leaks), Medium (clutter, old tags), or Low (clean, guarded, trained) risk. Manufacturing causes over 400,000 injuries each year in the United States (Occupational Safety and Health Administration 2024 data); dust and machines start 20% of factory fires (National Fire Protection Association). Average fire claim: $50,000+. Prevent with Occupational Safety and Health Administration machine guarding rules and National Fire Protection Association dust standards.
THE BASICS: HOW MANUFACTURING FACILITIES WORK
Manufacturing facilities make products by cutting, shaping, painting, and assembling materials like metal or wood. Machines do most work, but people guide them.
Simple Types of Work:
- Machinery Use: Saws, presses, and drills shape parts.
- Forklifts: Move heavy loads around.
- Paint Booths: Spray color on items in closed areas.
Other Tasks: Sanding makes dust, welding makes sparks.
Key Tools:
- Machines: Cut or bend materials.
- Forklifts: Lift trucks for boxes.
Paint Systems: Booths with fans to pull fumes.
Why Inspect: Dust can explode, machines cut fingers, forklifts tip over—most problems from clutter or missing guards.
Easy Fact: Facilities build cars, furniture, or tools—safe with clean air and guards, risky without.
INSPECTION CHECKLIST PAINT BOOTHS
o Fire suppression system inside booth has current service tag (last 6 months) Why: Dumps foam on paint fires fast.
o Booth fans pull air strong, filters clean Why: Pulls fumes away to stop breathing problems.
o No dust or paint buildup inside Why: Buildup starts fires.
o Doors close tight, lights explosion-proof Why: Stops sparks from igniting vapors.
MACHINERY
o Guards on blades and belts, no gaps Why: Stops hands from touching moving parts.
o Emergency stop buttons red and easy to reach Why: Quick shutoff if caught.
o Machines stable, no loose bolts or shakes Why: Shaking causes breaks or falls.
FORKLIFTS
o Tires good, no leaks, seatbelts work Why: Flat tires tip over.
o Horn and lights working, no blind spots Why: Warns people nearby. o Loads stable, not too high or heavy Why: Stops tipping or dropping.
DUST CONTROL
o Dust collectors on, bags not full Why: Wood or metal dust explodes if thick. o Floors swept daily, no piles Why: Dust slips people or catches fire.
o Masks worn near dusty machines Why: Protects lungs from fine particles.
FIRE PREVENTION
o Flammable cabinets metal, doors close tight, labeled “Flammable” Why: Keeps paint and solvents from sparking.
o Dirty rags in metal cans with tight lids Why: Wet rags self-heat and start fires. o Signs clear: “No Smoking,” “Flammable Area,” “Fire Extinguisher” Why: Warns workers of danger.
o Fire extinguisher near machines and paint, current tag Why: Puts out small sparks fast.
o No smoking near paint or dust Why: One spark starts big fire.
o Flammable liquids in small amounts, locked away Why: Stops vapors from building up.
FACILITY FIRE ALARMS & SPRINKLERS
o Fire alarm system serviced – annual tag current (last 12 months) Why: Proves full test and battery check.
o Smoke alarms beep when tested, no dust Why: Warns of fire early.
o Sprinkler system serviced – annual tag current (last 12 months) Why: Proves flow test and no clogs.
o Sprinkler heads clean, nothing within 18 inches Why: Water sprays free in fire. o Alarm panel green light, no trouble beeps Why: System ready to call help.
o Fire doors close tight, no props Why: Stops smoke spread.
SPRINKLER RISER & FIRE DEPARTMENT CONNECTION
o Riser room door unlocked, area clear of storage Why: Firefighters need fast access.
o Siamese caps on tight, no missing or painted Why: Lets fire trucks pump water in.
o Fire department connection sign visible: “Sprinkler Connection” Why: Guides fire crew quickly.
GENERAL SAFETY
o Aisles clear, at least 3 feet wide Why: Room for safe walking.
o Electrical cords not frayed, outlets not overloaded Why: Stops shocks or fires. o Staff trained yearly on safe use Why: Cuts accidents by half.
QUESTIONS TO ASK MANAGER
1. “When was the last full safety check? Can I see the log?”
2. “Paint booth suppression—serviced when? Tag current?”
3. “Flammable cabinets and rag cans—used right?”
4. “Fire alarms and sprinklers—annual service tags?”
5. “Riser room clear? Fire department connection caps on and signed?”
6. “Machines—all guarded? Forklifts—drivers trained?”
RISK LEVELS
- High = No suppression tag, open rag cans, blocked riser, no flammable liquids cabinet → Suggest attention immediately, fix now
- Medium = Clutter, old tags → Fix in 30 days
- Low = Clean, tagged, trained → Best practice
LCA Certified Inspector “Guard it. Clean it. Service it.” Resources:
- Occupational Safety and Health Administration Machine Guarding Rules
- National Fire Protection Association Dust and Paint Booth Standards
- National Institute for Occupational Safety and Health Manufacturing Guide
Safety by Design Factory Checklist
Disclosure: This guide highlights common risks but is not exhaustive. Always verify local codes and carrier guidelines.