Manufacturing Risk Engineering Success Stories

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Proactive Risk Engineering for Manufacturing Companies

Explore how manufacturing companies partner with The Hartford’s Risk Engineering team to identify jobsite risks, improve safety practices and help reduce losses across complex projects.
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Protecting Operations by Addressing Critical Fire Hazards

By addressing critical fire hazards, this furniture manufacturer partnered with Risk Engineering to identify gaps, invest in key upgrades and strengthen overall workplace safety.

The Risk

A furniture manufacturing customer had unresolved safety issues, including an inoperable fire suppression system, poor ventilation and hazardous conditions in the ignitable liquid room. This created a high risk of a major fire and potential operational disruption.

Implemented Solutions

Our Risk Engineering consultant met with the customer’s leadership to address risks, leading to an investment of over $62K in improvements. These improvements included repairing the spark detection system, adding ventilation and removing ignition hazards.

Success

The fire risk was significantly reduced, protecting a $3.5M new dust control system and improving safety and operations for the customer.

More Success Stories

A manufacturer faced ongoing injury risks from manual lifting. Learn how targeted technology and equipment upgrades helped reduce exposure and streamline operations.
 
The Risk  Implemented Solutions  Success 
A customer’s press operation required manual lifting and positioning of heavy panels, which created significant ergonomic strain for workers. This had already resulted in a prior injury and exposed the customer to ongoing safety risks and potential losses.  Our Risk Engineering consultant partnered with the customer and used The Hartford’s TrueMotion technology, powered by TuMeke, to clearly demonstrate the ergonomic risks and build a strong business case for change. This led the customer to invest over $35K in a vacuum lift system to eliminate manual handling.  The new system helped the customer improve worker safety by removing a key risk exposure, creating a more efficient process and generating an estimated ROI of $98K. 
Learn how targeted fire protection improvements helped a food processing facility reduce fire risk and maintain business continuity.
 
The Risk  Implemented Solutions  Success 
A food processing facility operated a high-temperature gas-fired oil cooker without a fixed fire suppression system. This created a significant risk of fire, direct property damage and business interruption.  Our Risk Engineering Consultants partnered with the customer to install a $244K fixed CO₂ fire suppression system and upgraded the sprinkler protection to strengthen the fire controls around the cooker and exhaust system.  The enhancements significantly reduced fire risk and protected operations. This helped the customer avoid potential losses up to $5M and achieve a strong 20:1 Return on Investment (ROI). 
Recurring roof leaks were damaging high-value inventory. Learn how advanced imaging technology helped pinpoint hidden issues, enabling targeted repairs that protected inventory and reduced costly disruptions.
 
The Risk  Implemented Solutions  Success 
A customer experienced ongoing roof leaks over several years that were damaging their high-value inventory, including finished grandfather clocks worth up to $10,000 each, with the root cause remaining unidentified.  Our Risk Engineering consultant used thermal imaging technology to pinpoint hidden moisture intrusion areas, enabling the roofing contractor to accurately locate and repair the leaks.  The fix prevented further product losses, protecting valuable inventory and delivering an estimated $100K in savings with a 50:1 ROI for the customer. 
Learn how a customer addressed recurring machine-related risks by implementing targeted safeguards, helping protect workers and improve overall safety.
 
The Risk  Implemented Solutions  Success 
A customer’s facility faced a history of severe injuries, which included amputations. This resulted in over $10M in losses and recurring incidents each year, putting employees at high risk.  Our Risk Engineering consultant partnered with the customer to implement a systematic machine safeguarding plan, including a $21K investment in enhanced machine guarding to their Chipper Deck.  The improvements significantly increased worker safety while delivering an estimated $850K ROI, helping the customer reduce injuries and create a safer, more sustainable operation.
A major facility upgrade introduced potential ergonomic risks during implementation. Learn how proactive risk engineering helped identify and reduce exposures, protecting employees while keeping production on track and improving efficiency.
 
The Risk  Implemented Solutions  Success 
A plant modernization project for a trailer manufacturer introduced new equipment and processes that could have created ergonomic risks. Without intervention, these changes could have increased the likelihood of employee injuries and disrupted operations.  Our Risk Engineering consultant proactively partnered with the customer to adjust their modernization plan. The Hartford’s TrueMotion technology, powered by TuMeke, was used to identify risks and deliver targeted improvements. These solutions protected employees while keeping the $12M modernization project on schedule and running efficiently. The improvements enhanced worker safety and increased production by up to two trailers per line per shift. This resulted in a remarkable 996% ROI, enabling the customer to modernize safely while boosting operational performance.