Manufacturing Safety Essentials - Part 2: Implementing Successful Safety Programs

A written policy is only the beginning. For California manufacturers facing high injury rates and strict Cal/OSHA oversight, the real challenge lies in translating safety intentions into consistent, effective practices on the ground.

In Part 2 of our Manufacturing Safety Essentials blog series (check out Part One here if you missed it), we’ll explore what it takes to implement safety programs that make a real difference.

Topics include:

• Why safety programs are critical in today’s environment
• How to build a Behavior-Based Safety (BBS) program
• Best practices for return-to-work strategies
• Key traits of high-performing safety programs
• Case studies from manufacturers leading by example

Let’s begin by examining why safety programs matter now more than ever...

Why Manufacturing Safety Programs Matter More Than Ever

California’s manufacturing sector is one of the most vital and most hazardous industries in the state.

The numbers paint a clear picture. In 2021, California’s manufacturing industry reported 3.6 injury and illness cases per 100 full-time employees, significantly above the national private industry average of 3.3. Many of these incidents stem from predictable but persistent hazards:

• Ergonomic injuries like repetitive strain and musculoskeletal disorders continue to dominate workers’ compensation claims.
• Chemical exposure and heavy equipment use frequently result in respiratory issues, skin irritation, and other long-term health problems.
• Slips, trips, and falls remain a leading cause of serious injury and death in manufacturing settings, according to Cal/OSHA.

In the sections that follow, we’ll explore what effective safety programs look like and how California manufacturers can implement them with lasting results.

Building a Behavior-Based Safety (BBS) Program That Works

When done right, behavior-based safety (BBS) programs can lead to significant reductions in workplace injuries — as much as 50% fewer reportable incidents compared to facilities without such systems in place.

BBS doesn’t just help to reduce risk. It also:

• Prevents accidents and injuries
• Increases employee engagement in safety efforts
• Promotes a culture of accountability and continuous improvement

The goal is to increase awareness, improve safety habits, and create an environment where safe actions are recognized and repeated.

8 Steps to Launching a Strong BBS Program

In our experience implementing behavior-based safety programs, we’ve identified 8 essential steps to success:

1. Secure Leadership Buy-In & Set Clear Objectives

A BBS initiative needs visible support from the top. Leaders should help define the purpose of the program and communicate why it matters.

2. Form a Steering Committee

Include representatives from leadership, management, and frontline staff. The committee will guide rollout, implementation, and oversight.

3. Identify Key Safety Behaviors to Influence

Use past loss data, incident reports, and near-miss statistics to pinpoint behaviors that frequently lead to injuries.

4. Train Observers and Participants

Observers must understand how to recognize safe and unsafe behaviors, provide feedback, and track progress without causing fear or backlash.

5. Implement Regular Observations and Feedback Loops

Set a cadence for safety observations and ensure employees receive constructive, blame-free feedback.

6. Record and Analyze Data

Collect and review data to track trends, identify weak points, and adjust strategies over time. Observations, near misses, and onboarding outcomes all provide useful insight.

7. Communicate Results and Celebrate Successes

Recognition reinforces good behavior. Celebrate safe practices publicly to build morale and momentum.

8. Commit to Continuous Improvement

BBS isn’t static. Review data, refine processes, and evolve with your workforce.

For manufacturers looking to reduce risk while strengthening operations, BBS offers a practical, proven model. Take a look below for an example of Tesla’s success with this philosophy as well as a few other case studies to inspire your next safety program.

Return-to-Work Programs: A Missed Opportunity

When structured well, a return-to-work (RTW) program not only shortens recovery timelines and lowers insurance claims but also boosts productivity by reinforcing that injured employees are still valued contributors.

However, RTW programs are often reactive. Data shows that approach comes at a cost:

• 87% of employees at companies with formal RTW programs return to work within 90 days
• That figure drops to 68% for companies without such programs

The longer an employee remains out, the harder (and more expensive) it becomes to reintegrate them. Having a well-defined RTW framework in place makes it easier to act quickly when injuries occur.

Best Practices for an Effective RTW Program

To maximize the impact of a return-to-work program, manufacturers should consider the following steps:

Assess and Establish the Need

Recognize RTW as a core business function, not just an HR formality.

Develop a Clear RTW Policy

Document expectations and procedures for injured employees returning to modified or transitional roles.

Create a “Job Bank” for Modified Duties

Identify light-duty roles in advance so accommodations don’t have to be created on the fly.

Engage Healthcare Providers

Work proactively with occupational clinics and industrial physicians. These providers can be powerful allies when included in the RTW planning process.

Educate Supervisors and Employees

Help your team understand the purpose and value of transitional duties. Without buy-in, even the best-laid RTW plans can fall apart.

Monitor Progress and Communicate Expectations

Like any performance process, the RTW journey should include regular documentation, check-ins, and clear guidance.

Integrate with Your IIPP and Safety Culture

RTW should align with broader injury prevention efforts and be embedded in your company’s written safety program.

A strong RTW program bridges the gap between medical recovery and full reintegration. It minimizes downtime, supports injured workers, and contributes to a broader culture of accountability and care.

What Makes Safety Programs Successful?

What separates a safety program that simply checks the boxes from one that creates lasting change? The answer is simple: a strong safety culture.

Across a range of successful manufacturers, certain traits show up again and again. These commonalities offer a blueprint for companies looking to strengthen their approach…

Common Traits of Effective Safety Programs

• Strong Leadership Commitment: Leaders need to stay on top of regulations as well as implementation. Start at the top and model consistently at every level.
• Employee Involvement and Engagement: Workers should play an active role in identifying risks, reporting near misses, and shaping improvements.
• Specific Objectives: Programs should have clearly defined goals, whether that’s reducing ergonomic injuries or improving response to incidents.
• Regular Safety Training: Ongoing education (not one-off sessions) helps embed safety habits into everyday routines.
• Clear Communication Channels: Employees need safe, accessible ways to report hazards and suggest changes.
• Proactive Risk Identification: Near-miss tracking, behavior observation, and regular audits are essential to spotting issues early.
• Performance Metrics and Monitoring: Data-driven analysis helps refine strategies and demonstrate progress to internal stakeholders and regulators alike.

These characteristics don’t just make programs more compliant, but far more effective. As we’ll see in the next section, some of California’s leading manufacturers have taken these principles and translated them into measurable success on the ground.

Case in Point: Safety Programs in Action

For California manufacturers looking to improve safety outcomes, it’s not always about reinventing the wheel. In many cases, the most effective approach is to study what’s already working and adapt those lessons to your own environment.

CalPortland: Building Engagement from the Ground Up

As a large cement and construction materials company, CalPortland faced significant safety challenges. Their solution was a “Safety Excellence” program focused on employee engagement and proactive safety measures. Key components included:

• Rigorous safety training
• Regular risk assessments
• A behavior-based safety initiative encouraging workers to report hazards and suggest improvements

The results were striking: a 70% reduction in incident rates over five years, and more than a million hours worked without a lost-time injury.

Tesla: Using Data to Drive Safer Workflows

Tesla’s Fremont facility had to overcome high injury rates tied to fast-paced production goals. Their turnaround began with a comprehensive behavior-based safety program that incorporated:

• Classroom and hands-on safety training
• Safety champions providing regular feedback
• Real-time data analytics and AI to monitor ergonomic risks

With this data-driven approach, Tesla reduced ergonomic-related injuries by 25% in the first year.

Toyota: Audits and Accountability in Long Beach

Toyota’s Long Beach site implemented a “Zero Incident” campaign centered on layered safety audits and near-miss reporting. The program emphasized shared responsibility, with employees and management both participating in inspections and improvements.

Their sustained focus on audits and early intervention led to a near-zero reportable incident rate, maintained over multiple years.

Dole: Elevating Safety Through Training and Preparedness

Dole Fresh Vegetables focused its safety efforts on continuous improvement, emergency preparedness, and team-wide awareness. They conducted:

• Weekly safety meetings
• Frequent drills for evacuation and first aid
• Regular risk assessments and open forums for safety concerns

The outcome: a 40% reduction in both minor injuries and serious incidents over three years.

Key Takeaways from the Field

Whether it's through data, training, engagement, or emergency planning, each of these manufacturers turned intent into impact. The case studies reinforce a simple point: successful safety programs share common foundations, but their execution is tailored to the unique challenges of the workplace.

Workplace Safety: A Key Driver of Organizational Success and Growth

Preventing injuries is goal #1 of any safety program; but beyond that, a smartly designed and well-executed program will cut costs, improve morale, and protect operations from regulatory disruption.

Using the principles outlined in this blog, you can immediately begin to implement behavior-based safety, establish effective return-to-work policies, and build a culture that supports long-term success.