Manufacturing Plant Achieves Zero Slip-and-Fall Incidents
Published July 10, 2024
Client Overview
Client
Precision Components Manufacturing
Location
Chicopee, MA
Facility Size
85,000 sq ft
Employees
120
The Challenge
Workplace safety incidents and heavy industrial cleaning challenges
Precision Components Manufacturing operates a high-volume metal fabrication facility running two shifts daily. The 85,000 square foot plant produces precision-machined components for aerospace and automotive industries, with strict quality and safety requirements.
The facility was experiencing 3-4 slip-and-fall incidents per year, primarily caused by metal shavings, coolant residue, and oil accumulation on production floor surfaces. Each incident resulted in workers' compensation claims, OSHA recordable injuries, lost work time, and potential liability. Their insurance carrier was threatening to raise premiums unless safety metrics improved.
The plant's previous cleaning approach relied on day-shift production workers doing basic sweeping, with a small night crew handling restrooms and offices. Production floors received irregular attention, and the heavy industrial soil—cutting oils, metal particulate, hydraulic fluid—required specialized equipment and expertise that the facility didn't have in-house.
The facility manager needed a professional industrial cleaning partner who understood manufacturing environments, could work safely around production equipment, and had the specialized equipment to handle heavy-duty cleaning challenges. Most importantly, they needed measurable improvements in workplace safety.
Key Pain Points
- 3-4 slip-and-fall incidents per year (OSHA recordables)
- Workers' compensation claims averaging $15,000 per incident
- Insurance carrier threatening premium increases
- Metal shavings, coolant, and oil accumulation on floors
- No specialized industrial cleaning equipment
- Production workers spending time on cleaning instead of manufacturing
- Irregular cleaning schedules disrupting production flow
- No documented cleaning protocols for regulatory audits
Our Solution
Anderson Cleaning Company deployed our industrial cleaning division with specialized training and equipment for manufacturing environments. We conducted a comprehensive facility assessment, identifying all high-risk areas, traffic patterns, and production schedule constraints.
We implemented a daily floor care program using industrial auto-scrubbers with degreasing solutions designed specifically for manufacturing environments. Our team performs systematic cleaning between first and second shift (2:30 PM - 5:00 PM), removing metal shavings, coolant residue, and oil accumulation before the next production cycle begins.
For heavy soil areas around CNC machines and cutting stations, we use industrial wet/dry vacuums to capture metal particulate and fluids immediately. We installed slip-resistant matting in high-risk zones and established a rapid-response protocol for any spills during production hours.
Our team received extensive safety training specific to this facility, including lockout/tagout procedures, compressed air safety, and proper PPE for industrial environments. All cleaning staff are equipped with steel-toe boots, safety glasses, and high-visibility vests. We coordinate daily with the facility manager to ensure cleaning never interferes with production schedules.
To demonstrate results, we implemented a safety tracking dashboard that monitors floor condition audits, incident reports, and inspection findings. The facility manager receives weekly reports showing cleaning completion, any safety concerns identified, and trend data.
Services Implemented
- Daily industrial floor care with auto-scrubbers
- Inter-shift cleaning (between 1st and 2nd shift)
- Metal shavings and coolant removal
- Industrial degreasing and oil removal
- High-risk area matting installation
- Rapid-response spill cleanup protocol
- Office and restroom facility maintenance
- Safety training and compliance documentation
- Weekly reporting and safety tracking dashboard
Timeline
21 days from initial assessment to full program launch
The Results
"Anderson Cleaning Company has been a game-changer for our safety program. Their industrial cleaning expertise and commitment to working within our production schedule has eliminated our slip-and-fall problem entirely. The $45,000 in annual savings more than pays for their service."
Additional Outcomes
- Insurance carrier removed threat of premium increase
- Achieved 18+ months without a slip-and-fall incident
- Production workers freed up to focus on manufacturing tasks
- Improved floor appearance during customer facility tours
- Passed surprise OSHA inspection with zero citations
- Client expanded service to include warehouse and loading dock areas
Ready for Similar Results?
Let's discuss how Anderson Cleaning Company can solve your facility's challenges and deliver measurable results.