Navigating Safety & Compliance in Manufacturing: Key Findings from the OH&S Report

More than 70% of manufacturing facilities still rely on outdated manual systems for visitor management and safety protocols, according to a recent report by OH&S Magazine. In an industry where precision and compliance are critical, these manual systems are inefficient but risky. 

To explore the challenges and solutions more deeply, sponsored by iLobby, OH&S Magazine partnered with Agency@1105 to survey manufacturing professionals, of whom nearly 80% were health and safety specialists. Their findings highlight the urgent need for digital transformation to ensure safer, more compliant, and future-ready operations.   

While the report offers far more insights than we will discuss in this blog, we’ve picked out what we consider the top key findings on navigating safety and compliance from manufacturers—let's dive in! 

1. Outdated Visitor Management Systems Are a Risk 

As mentioned above, over 70% of manufacturing facilities still rely on outdated methods to manage visitor access. These manual systems are inefficient; they can create significant risks for your organization.  

Many professionals—about 25%—reported challenges in maintaining accurate visitor records, leading to gaps that can affect compliance and safety. In an industry where every detail matters, these shortcomings can have serious consequences.  

The reliance on manual systems can put your facility at risk of non-compliance, operational shutdowns, and costly fines. One of the biggest challenges manufacturers have with their current process is inaccurate or incomplete visitor records, followed by time-consuming processes, inability to keep track of visitors, and poor access to data and records. Working frequently with EHS managers, we understand the weight of these responsibilities and the importance of fostering a safe, secure and compliant environment for everyone.  

Embracing digital solutions is a step toward operational efficiency; it's a commitment to safeguarding your team and ensuring that your facility meets regulatory standards. Now is the time to prioritize modernizing your visitor management system for safety, compliance, and peace of mind. 

2. Widespread Compliance Challenges: A Call for Better Solutions

More than 40% of manufacturing facilities face significant difficulties with data access and incomplete visitor records, while 45% of professionals cannot confidently assert the accuracy of their visitor logs. These statistics highlight a pervasive issue that many EHS managers face daily.  

In an industry where compliance with regulations such as OSHA and ITAR are non-negotiable, having inaccurate records can lead to severe consequences, including hefty fines, reputational harm, and even operational shutdowns.   

Implementing robust visitor management systems that ensure your records are accurate and readily accessible for audits and regulatory scrutiny is recommended. Prioritizing these solutions protects your organization and fosters a culture of safety and accountability. Embracing digital transformation in visitor management is building the resilient, compliant facility your team deserves. 

Related content: Top Tips for Tackling Audits and Ensuring Regulatory Compliance

3. The Need for Real-Time Visitor Tracking and Data Analytics

51% of survey respondents identified real-time visitor logs and reporting as a critical need, yet most facilities still lack this capability. Additionally, 41% expressed a desire for enhanced reporting and analytics in their emergency management systems, and over 40% reported lacking access to complete records.  

For a modern, fast-paced manufacturing environment, real-time tracking is crucial for maintaining security, optimizing operational efficiency, and ensuring effective emergency preparedness. Without this capability, facilities miss vital insights and may face slow response times during critical situations.  

Implementing robust data analytics helps identify visitor patterns but also supports the improvement of safety protocols, enabling informed decision-making.  

For EHS managers, investing in real-time tracking and analytics is a matter of convenience but a proactive approach to safeguarding your workforce and enhancing overall facility performance. 

Related content: How to Track Employees & Visitors During an Evacuation

4. Automation Saves Time and Enhances Safety

Automation in visitor management is becoming increasingly vital, with features like digitized check-ins, automated badge printing, and compliance documentation playing a critical role in operational efficiency. Despite this need, only 15% of survey respondents reported having systems capable of digitally provisioning secure visitor credentials.  

The benefits of automation extend far beyond mere convenience. By streamlining processes, facilities can significantly reduce administrative burdens, improve accuracy, and ensure safety. For EHS managers in manufacturing, where safety is a top priority, automating visitor management tasks saves time and mitigates risks associated with manual processes.  

Embracing these automated solutions can lead to cost savings and enhance overall operational performance, allowing teams to focus on what truly matters—creating a safe and efficient work environment for everyone. 

Related content: Simplifying Visitor Management in Factories & Manufacturing

5. Emergency Preparedness and Response Gaps 

A significant challenge in emergency preparedness is highlighted by the fact that 76% of facilities still rely on manual logbooks or lack systems to track visitors during critical situations. Additionally, 54% of respondents expressed a strong desire for improved visibility into visitor status during emergencies, while only 23% have implemented systems capable of digitally tracking evacuee status. 

In the face of an emergency, real-time tracking of visitors and contractors ensures the safety of everyone on-site. The inability to monitor evacuee status presents serious risks, potentially jeopardizing personnel safety and complicating evacuation efforts.  

By adopting digital systems, facilities can enhance their emergency response capabilities through improved real-time communication and tracking. This proactive approach strengthens emergency preparedness but also fosters a culture of safety, enabling EHS managers to safeguard their teams more effectively. Investing in these solutions can make a profound difference when every second counts. 

Related content: Effective Emergency Planning: A Five-Step Guide to Ensuring Safety & Compliance

6. Cross-Facility Visibility is a Game-Changer

Digital platforms provide a significant advantage by offering cross-facility visibility, enabling manufacturers to monitor multiple sites from a centralized system. Yet, 38% of surveyed EHS managers indicated they struggle to communicate with visitors, while 15% reported challenges communicating with anyone during critical situations.  

Maintaining a unified view of operations is vital for organizations operating across various facilities. This centralized visibility ensures consistency in safety protocols and enhances emergency response coordination. In times of widespread incidents, having the ability to assess the status of all locations quickly can make a profound difference.  

It strengthens operational resilience and empowers EHS managers to act swiftly and effectively, safeguarding personnel and resources. Embracing cross-facility visibility is about efficiency; it's about fostering a cohesive safety culture that spans the entire organization. 

Related content: 5 Tips for Multi-Location Visitor Management

7. Opportunity to Automate Safety Training

Despite the critical importance of safety training for visitors and contractors, only 10% of facilities entirely automate this process with digital records. Alarmingly, 36% still rely on manual methods, which can be time-consuming and prone to errors.  

Automating safety training presents a valuable opportunity to enhance preparedness and minimize emergency risks. Facilities can reduce liability and bolster overall safety by providing all visitors with the necessary knowledge to navigate potential incidents. For EHS managers, implementing automated training solutions means ensuring every individual on-site is well-informed and ready to act in a crisis.  

This proactive approach fosters a culture of safety but also reinforces compliance with regulatory standards. Embracing automation in safety training is a vital step toward creating a secure and efficient environment for everyone involved. 

Related content: How to Speed Up Emergency Response Times in Your Facility