One of the most impactful lessons for workplace safety comes from the story of Day Davis, a young employee who lost his life on the first day of a new job at a bottling plant in Jacksonville, Florida. The video highlights how a lack of proper safety practices and communication led to the fatal incident.
At Valence Industrial, we’re passionate about preventing tragedies like this. That’s why we work closely with manufacturers to design and implement safety solutions that are tailored to their specific warehouse needs.
The Hidden Costs of Turnover Rates
Even subtle, unsafe conditions can drive employees to competitors in today’s tight labor market. Workers increasingly prioritize safety when choosing where to work, and unsafe conditions create a revolving door that’s expensive to maintain.
When safety concerns drive turnover, you face these costs:
- Recruitment and hiring expenses
- Onboarding and initial training programs
- Ongoing learning and training investments
- Lost productivity during unfilled positions
This OSHA video vividly illustrates how quickly a struck-by accident can result in fatal consequences. It emphasizes the reality that when safety isn’t prioritized, employees may leave.
Smart Safety Investments That Pay for Themselves
The good news? Companies that invest in proactive safety solutions often see immediate returns through reduced insurance premiums, improved employee retention, and enhanced efficiency in their warehouses. When safety systems are designed correctly for your specific environment, they protect your workforce while supporting productivity goals.
Here’s how we’ve helped manufacturers create safer workplaces that actually improve their bottom line.
Auto Industry: Standard & Custom Guardrails
Improper machine guarding ranks as one of the most frequent causes of OSHA citations. When an incident occurs, your employees’ compensation could jump from 5% to 20% overnight.
The Challenge
The world’s #1-ranked automotive company needed nearly two miles of aisle guarding in its new Alabama factory to protect workers from automated equipment on the floor. The project required 2,700 feet of guarding: 1,760 feet of standard fencing plus 950 feet of custom sections to keep a distance between autonomous robots that were being charged.
How Valence Solved It
Valence Industrial’s engineering team walked the factory floor and mapped a 3D model of the plant using AutoDesk. Through collaborative design and field measurements, our team identified critical design adjustments:
- One custom section encircled autonomous robotics so they could load and charge. While they have safety features, there is always a chance that someone may be moving too quickly and run into one of the robots.
- One section of the fencing had a 90-degree L-shaped turn. While walking the floor, we realized that autonomous robotic tuggers pulling parts around the floor wouldn’t be able to make the turn, so we had to change it to a 45-degree turn.
- One custom frame required shorter widths and heights because we realized, after walking the floor, that the tuggers and forklifts that were backed into charging systems were lower than previously believed.
- The dimensions for a robotic training center, where employees were trained to use robots, had changed since the client’s prints were developed. We realized it while walking the floor and made that correction to avoid any issues in the future.
The Result
- Nearly two miles of standard and custom aisle guarding were installed to protect employees from getting too close to the automated robots.
- Guards were created that actually fit their factory floor conditions.
- Safer, more efficient human-to-robot interactions occurred throughout the facility.
Read the full case study here.
Custom Solutions for Extreme Temperature Challenges
The Challenge
International Crankshaft Inc. faced a critical problem with their forging operation. Their robotic gripper system, responsible for transferring hot forgings between processes, was deteriorating rapidly due to heat damage. The failing equipment not only increased production schedules but also created dangerous conditions where workers could be exposed to extremely hot materials.
How Valence Solved It
We analyzed every component — seals, rods, plates, and all moving parts — to determine which parts could be refurbished and which needed complete replacement. This gave us the insight we needed to determine what materials and processes to recommend.
Heat-Resistant Material Selection:
- Hardened tool steel for maximum durability under extreme temperatures
- Stainless steel components for long-term use and heat resistance
Our Complete Approach Included:
To make sure the changes met the customer’s needs and performed reliably, Valence followed a structured process to manufacture the solutions:
- Walk the plant and take notes of issues the customer is experiencing
- 3D modeling
- Manufactured prints
- Saw cutting
- Plasma burning
- Welding and assembly
The Results
- The heat-resistant gripper system minimized the risk of exposing workers to dangerously hot materials, preventing potential burn injuries.
- The new design, utilizing tougher materials, ensures consistent performance under extreme heat conditions, thereby eliminating unexpected production shutdowns.
- By refurbishing existing equipment where possible, we saved the customer significant costs and lead time compared to purchasing entirely new systems.
Read the full case study here.
A Partner For Safety
Explore our manufacturing capabilities today to see how we can help solve workplace safety issues you are having. Or, if you have a question, reach out to us at 877-330-2354 or submit a request through our contact us page.
