ISO 45001 in industrial manufacturing – specific requirements and key risks

Manufacturing plants are among the work environments with the highest level of risk complexity. Machinery, chemicals, noise, shift work and high pressure to meet production targets create an environment in which the risk of an accident is structurally higher than in the service sector or an office. ISO 45001 is a tool for managing these risks in a systematic way – a mechanism for the continuous identification of hazards and continuous improvement, rather than a set of procedures that are simply filed away.

The specific nature of a production facility and the requirements of the standard

Industrial production is characterised by three features that influence how ISO 45001 is applied.

1. The complexity and diversity of hazards. A single facility may be subject to mechanical, chemical, physical (noise, vibrations, temperature), biological and ergonomic hazards simultaneously. The standard requires a comprehensive identification of hazards covering all categories – not just the most obvious ones.

2. Shift work, which generates specific risks: fatigue, reduced alertness at night, and changing team compositions. Risk assessment must take into account working conditions at different times of the day, not just the standard working day.

3. A high proportion of subcontractors and temporary workers. Employment agencies, service providers and renovation contractors operate on the premises and are covered by the organisation’s health and safety system. ISO 45001 requires that health and safety requirements be defined for all persons working under the organisation’s control and that compliance with these requirements be verified.

The most common hazards in manufacturing and how the standard helps to manage them

• Machinery and equipment – risks of crushing, cutting and entanglement. ISO 45001 requires a risk assessment for each workstation, the implementation of a hierarchy of control measures (guards, interlocks, signalling) and safe operating procedures, including lockout/tagout during maintenance work.
• Chemicals and dust – hazards with delayed health effects. The standard requires the identification of all substances used, an assessment of workers’ exposure and verification of compliance with occupational exposure limits (OELs), followed by the application of a hierarchy of control measures – from substitution, through encapsulation, to personal protective equipment.
• Noise and vibrations – the most common occupational diseases in Polish industry. A systematic hearing protection programme is required: measurements, technical controls, hearing protectors and regular monitoring of workers’ exposure, with analysis of the results.
• Working at height and the risk of falls. This applies to many workplaces during maintenance, assembly and repair work. The standard requires a hierarchy of collective measures over individual ones, as well as documented rescue procedures.
• Ergonomic hazards – musculoskeletal strain. One of the main causes of absenteeism in manufacturing. ISO 45001 requires ergonomic hazards to be taken into account in risk assessments and corrective actions – such as job rotation, adjusting the height of workstations and mechanising manual tasks.

ISO 45001 in tenders and the manufacturing supply chain

ISO 45001 certification is becoming increasingly important for manufacturing plants in the marketplace. Large corporations and companies in the automotive sector use it as a criterion for supplier qualification – alongside ISO 9001 and IATF 16949. A plant without a certified health and safety management system may be excluded from qualification procedures regardless of the quality of its products.

At the same time, regulatory pressure relating to ESG is growing – non-financial reporting increasingly includes health and safety indicators: the number of accidents, absenteeism and near-miss incidents. ISO 45001 certification is one of the most effective ways of demonstrating a commitment to employee safety to investors, customers and regulatory bodies.