Lone Working in Manufacturing: A Brief Guide
Learn about lone working in manufacturing and how to better protect your workers when they’re working alone.
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Learn about lone working in manufacturing and how to better protect your workers when they’re working alone.
Lone working in manufacturing is essentially a situation where employees do the job on their own, without direct supervision or support. It’s pretty common—whether it’s a maintenance worker fixing equipment in a quiet corner of the plant, or someone running a machine on a late shift. Working alone in manufacturing can bring its own set of challenges, like feeling isolated or not having anyone close by to help if something goes wrong. That’s why it’s important to understand these situations and put the right safety measures in place — to make sure lone workers stay safe, supported, and connected, even when they’re working solo.
Prioritizing safety in manufacturing is essential for protecting employees’ health and well-being, while also minimizing workplace accidents and associated costs. It plays a crucial role in risk management, helping to identify and mitigate potential risks associated with lone working, such as accidents, injuries, or even violence. By having a lone working safety guide in place, manufacturing companies organizations can implement measures to minimize these risks and ensure a safer working environment for their lone workers.
Lone workers in manufacturing face several risks and hazards, including the following:
Handling dangerous equipment or machinery
Working with hazardous chemicals or substances
Lifting and working with heavy loads
Performing tasks at heights
Working shifts or irregular shifts
Facing security risks from intruders or vandalism
Experiencing stress and anxiety
Different territories and agencies often have their own lone working regulations for lone worker safety in manufacturing jobs. These legal requirements aim to protect workers and ensure workplace and environmental safety. Compliance with these ascertains their safety and shields employers from legal and financial risks.
In the US, the Occupational Safety and Health Administration (OSHA) has set regulations to ensure and manage the safety of lone workers in the manufacturing industry. Employers are responsible for regularly monitoring lone workers through visual or verbal check-ins, as outlined in OSHA 1915.84: Working Alone. This includes conducting scheduled check-ins during shifts and confirmation at the end of each shift to ensure their well-being. To further reduce the risk of injury, organizations can implement a mobile platform that allows workers to easily access company policies and request assistance when necessary.
For example, consider a maintenance technician working alone during a night shift in a remote part of a large factory. Under OSHA 1915.84, the employer must regularly check in on this worker-either visually or verbally-throughout the shift and confirm their well-being at the end of the assignment. This process ensures that if the worker were to experience a medical emergency, injury, or become incapacitated, the absence of a check-in would trigger a prompt response, potentially preventing a serious outcome.
Another OSHA guideline relevant for lone workers in manufacturing is the General Duty Clause, which calls for employers to protect all workers, including those alone, from hazards. For lone workers in unpredictable settings where they may face various manufacturing hazards they may not be prepared for, this means regular check-ins, clear communication processes, and updated risk assessments to address emerging risks.
Meanwhile, in the UK, while there are no specific lone working laws for manufacturing jobs, the primary legislation that covers occupational health and safety are the Health and Safety at Work etc. Act 1974, along with its later amendments, and the Management of Health and Safety at Work Regulations 1999. Under these regulations, employers are legally required to assess workplace risks and put preventative measures in place when any are identified. For those who work alone in the manufacturing industry specifically, it’s important that companies have a clear and thorough lone working policy. Ideally, each worker should receive a copy of this policy, and it should also be clearly displayed somewhere visible at the site or workplace, such as near machines, dusty locations, and other places where hazards are likely to be encountered.
Working alone in manufacturing environments can present unique safety challenges, where risks are heightened due to isolation from immediate support. Thankfully, technology is making a big difference in keeping lone workers safer. With around 53 million lone workers across the US, Canada, and Europe, the absence of nearby coworkers or supervisors can lead to more severe outcomes in emergencies compared to those working in teams. Solutions like Mitti (by SafetyCulture) addresses these challenges by monitoring and streamlining risk identification and management through digital checklists, real-time data analytics, and automated reporting. These tools spot risks early and speed up response, helping prevent serious injuries.
The adoption of wearable devices, mobile safety apps, and Internet of Things (IoT) sensors has also made it significantly easier to report, record, and analyze safety hazards.
Panic button features integrated into safety apps now allow lone workers in the manufacturing industry to quickly alert employers with their real-time location in dangerous situations, ensuring rapid assistance. Also, automated check-ins enable employers to monitor worker locations in real-time so they can dispatch help efficiently if an emergency arises-even in. remote or hazardous environments.
Other features of Mitti (by SafetyCulture) designed for lone worker protection are the following:
GPS tracking and location monitoring
Alerts that can escalate to emergency services
Mobile check-in systems with configurable durations
Man down or incapacitation detection systems
Mobile-ready training solutions for orienting workers on proper lone working safety procedures
Mitti (by SafetyCulture) is a mobile-first operations platform adopted across the manufacturing, mining, construction, retail, and hospitality industries. It is designed to equip leaders and working teams with the knowledge and tools to do their best work—to the safest and highest standard.
Stay connected with your team and manage lone worker risks through location sharing and discreet panic alerts that can escalate to emergency services. Foster a culture of safety and transparency by enabling constant communication with lone workers, allowing them to perform tasks with configurable durations and check-ins.
✓ Save time and reduce costs ✓ Stay on top of risks and incidents ✓ Manage compliance with safety standards ✓ Enhance communication and collaboration ✓ Monitor worker condition ✓ Make data-driven business decisions
