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Manufacturing Quick Win. Prospect WINS.

WINS MANUFACTURING RESOURCE HUB

Build or Elevate your Risk Profile

Job Hazard Analysis (JHA), Safe + Sound JHA Series 1-3 of 6

Job Hazard Analysis: Why it Matters

  •  A JHA is a step-by-step process that looks for current and potential future hazards in a workplace. 
  • In this first video, an OSHA staff member explains why a Job Hazard Analysis (JHA) is an important part of a workplace safety and health program. 
  • The Safe + Sound Job Hazard Analysis video series explains the steps of a JHA. 


2 minute YouTube video, US Department of Labor

Job Hazard Analysis: Job Selection

  •  This video explains the process to select a job to analyze for hazards and how to include our workers in the JHA process.  


1 minute YouTube video, US Department of Labor

Job Hazard Analysis: Outline Job Steps

  •  This video explains how to review a job’s steps in depth with workers to determine how a job is done in practice. 
  • The Safe + Sound Job Hazard Analysis video series explains the steps of a job hazard analysis (JHA). 


2 minute YouTube video, US Department of Labor

JOB HAZARD ANALYSIS (JHA), SAFE + SOUND JHA SERIES 4-6

Job Hazard Analysis: Review Steps for Hazards

  •  Follow along to review the steps of a job outline for hazards, what to look for, and how to include workers in the process. 
  • The Safe + Sound Job Hazard Analysis video series explains the steps of a job hazard analysis (JHA). 


2 minute YouTube video, US Department of Labor

Job Hazard Analysis: Choose and Add Controls

  •  In this video, learn about the hierarchy of controls and best practices for controlling workplace hazards.  The Safe + Sound Job Hazard Analysis video series explains the steps of a job hazard analysis (JHA). 


3 minute YouTube video, US Department of Labor

Job Hazard Analysis: Monitor Controls and Continual Improvement

  •  This final video shares how to use a Job Hazard Analysis (JHA) for long-term hazard control with monitoring, continuous improvement, and keeping workers involved in the process. 
  • The Safe + Sound Job Hazard Analysis video series explains the steps of a JHA. 


2 minute YouTube video, US Department of Labor

Job Hazard Analysis (JHA) Generator, Manufacturing

OSHA Recordkeeping Forms and TIPS/ What is A First Aid Case?

OSHA LOG (OSHA 300, 300A, 301)

What IS AN OSHA first aid CASE?

What IS AN OSHA first aid CASE?

 Manufacturing facilities typically have higher volumes of injuries and illnesses due to machinery, repetitive tasks, and material handling. The OSHA Forms Packet contains the required 300 Log, 300A annual summary, and 301 incident report forms for maintaining accurate occupational injury and illness records.

Most manufacturing establishments with 20 or more employees must electronically submit their OSHA 300A data, and in many cases 300/301 data, through the Injury Tracking Application (ITA). Check OSHA’s coverage lookup tool to confirm your reporting obligations.

Accurate classification matters: many minor cuts, strains, and contusions qualify only as first aid and should not be entered on the OSHA 300 Log.

OSHA 300 Log, 300A, 301 Forms

What IS AN OSHA first aid CASE?

What IS AN OSHA first aid CASE?

What IS AN OSHA first aid CASE?

 Under OSHA’s recordkeeping regulation, first aid includes treatments such as using non-prescription medication at non-prescription strength, cleaning and bandaging wounds, applying hot or cold therapy, etc. (use the 29 CFR § 1904.7(b)(5)(ii) link below).

Because these cases do not involve medical treatment beyond first aid, days away from work, or restricted duty, they stay off the Log and do not affect your TRIR.

The OSHA Log and your Workers’ Compensation insurance system are two independent systems. While OSHA recordable cases are often also Workers’ Comp cases, they do not have to be, and a Workers’ Comp claim does not automatically make an injury OSHA recordable.


OSHA Definition of FIrst Aid Cases

CAL/OSHA FORM 300, 300A, 301)

What IS AN OSHA first aid CASE?

CAL/OSHA FORM 300, 300A, 301)

California employers use the Cal/OSHA Form 300 Log to record and classify work-related injuries and illnesses and to document the extent and severity of each case. When an incident occurs, enter the specific details of what happened and how it happened directly on the Log. The Cal/OSHA Form 301 Incident Report provides additional space to document the circumstances and contributing factors in greater detail.

At year-end, complete the separate Cal/OSHA Form 300A Summary, which shows the annual totals for each category. Post the Summary in a visible location from February 1 through April 30 so employees can review the injuries and illnesses that occurred in their workplace during the prior year.


Cal/OSHA Log Forms 300, 300A, 301

COMPARE YOUR Incident DATA to Others, Manufacturing/FIND SDS

Manufacturing, EMR and OSHA Recordable Rates

SAFETY RESOURCES FOR LEADERSHIP DEVELOPMENT/Fleet SAFTETY

Business Insurance/ Risk Management/ AI Changing Insurance

Business Insurance: General Liability, Umbrella Coverage, Commercial Auto & Workers’ Compensation

 • General Liability fundamentals: Understand what it covers (bodily injury, property damage, product liability, personal & advertising injury) and what it doesn’t (workers’ comp, professional liability, liquor liability, auto).

• Clarify Umbrella vs. Excess Liability: Learn the key differences, how umbrella policies “drop down” to cover gaps, self-insured retentions, and why these policies are only as strong as what they follow.

• Navigate Commercial Auto & Workers’ Compensation: Discover non-owned & hired auto coverage for businesses without vehicles, plus WC mandates, audits, experience rating, class codes, and owner opt-out considerations.

• Get practical risk management & contract advice: Expert tips on notifying insurers about business changes, contractual liability, additional insured requirements, determining proper limits, and tail coverage (ERP) for claims-made policies.

The National Law Review 58 minute YouTube Video.

Corporate Risk Management Basics

• Learn the fundamentals of risk management: How to identify, assess, and treat risks using likelihood vs. impact, controls, and the core strategies of avoid, mitigate, or transfer (including insurance) to protect people, property, profits, processes, reputation, and digital trust.

• Discover today’s biggest business loss exposures: Cyber/data breaches, supply chain & third-party risks, increasingly frequent weather events, liability litigation, strategic disruption, and reputational damage in a digital, interconnected world.

• Understand insurance’s critical role in risk management: How it converts uncertainty into known costs, encourages loss control through risk-sensitive pricing and deductibles, and why choosing the right broker/agent (experience, integrity, plain-language communication, industry expertise) matters.

• Build the right advisory team and avoid common mistakes: Key professionals every business owner needs (CPA, specialized attorney, insurance broker, IT/data expert, banker) plus pitfalls like complacency, underestimating maximum losses, siloed operations, and incomplete risk identification.

The National Law Review 60 minute YouTube Video.

How AI is changing insurance: Risk, accountability and trust

 Expert Analysis: Financial journalist Georgie Frost, Allianz UK CDO Akhil Lalwani, and Verisk Counsel Mary Bowie analyze AI's impact on the insurance industry. 

  • Risk and Regulation: The discussion highlights AI-driven exposures, data governance, and the imperative for fair, explainable, and accountable automated decisions.
  • Broker Evolution: Experts explore how AI is redefining the role of brokers amid shifting customer behavior and evolving regulatory landscapes.
  • Human-AI Collaboration: The episode explores future AI maturity in insurance, emphasizing the continued, irreplaceable role of human judgment.
  • Allianz 30 minute YouTube Video.

Fire Protection Strategy/ Hazard Id/ Safety Committees

PFAS Bans, Lithium-Ion, and More Emerging Risks Mean Your Fire Protection Strategy is Outdated

  •  Emerging risks are outdating traditional strategies: PFAS/AFFF bans (no universal replacement), lithium-ion thermal runaway (harder to suppress), supply chain delays, captives/risk retention, inaccurate valuations, evolving standards, and AI are increasing fire frequency/severity and turning manageable incidents into prolonged downtime and higher insurance pressure.
  • Business interruption now dominates losses: Interconnected risks, long equipment replacement times, and concentrated global supply chains mean fire impact often exceeds property damage; prevention and resiliency planning have become far more valuable.
  • Key vulnerabilities require holistic assessment: Production process shifts (e.g., early EV battery installation), flammable liquids/dusts, human factors, outdated suppression/detection systems, poor maintenance, and new renewable energy setups; engineers evaluate location, construction, processes, and controls during site visits.
  • Data-driven engineering improves outcomes: Accurate valuations, documented mitigation, centralized risk data, and AI tools strengthen risk quality, support captive capital management, enhance underwriter confidence, and deliver better resilience and insurance results.


TÜV SÜD. 52 minute YouTube Video.

Hazard Identification

 Oregon OSHA demonstrates a comprehensive workplace walkthrough to identify hazards and verify safety controls. The team follows a structured process to document issues, prioritize repairs, and implement corrective actions for improving employee safety. 


  • Oregon OSHA 9 minute YouTube Video.

OSHA Etool - Lockout-Tagout Interactive Training Program

Core Elements - Effective Safety Committee Meetings

 Dedicated forum for worker voice: Safety committees give workers a structured way to share ideas, suggestions, and concerns about hazards and procedures, directly engaging and empowering them to improve worksite conditions while boosting morale and performance.

  • Ongoing improvements through participation: Even plants that believe they already have strong safety see continuous gains; the Liberty Electric Power Plant has implemented hundreds of improvements over the years through its committee, with attendance rising from just a few people to as high as 90% of staff.
  • Identifying hidden hazards: Committees surface risks that managers often miss because they don’t perform the daily tasks; workers flagged rusting valve handles on a cooling water tower that could cause injury or equipment failure, leading to full replacement.
  • Worker-driven solutions: Frontline hourly employees are best positioned to spot practical issues; their recommendations (like the valve handle fix) prevent injuries such as back strains and demonstrate why broad participation is essential to effective safety programs.

USDOL YouTube 3 minutes

EMR EMOD WORKSHEET/ Safety Culture/ Work with Underwriters

Experience Rating Worksheet at a Glance

 A worksheet is issued to employers who qualify for experience rating and details the data used to calculate the experience rating modification (mod), with the top section listing the employer’s name, NCCI risk ID, production date, and effective policy date.

  • The summary section compares actual losses (reported by the carrier) against expected losses (based on the employer’s payroll size and class codes) to determine the mod.
  • The detailed section shows class codes, associated payroll, and expected losses on the left, with claim data and loss amounts on the right; these are totaled and summarized on page one, which may also include explanatory comments.
  • Viewers are directed to additional free resources and a webinar for a more in-depth explanation of the worksheet.

YouTube, Channel NCCI 2 minutes.

NCCI, ABCs of Experience Rating, 15 page pdf.

Going Beyond Procedure Creation – Changing Your Culture

  •  This webinar emphasizes shifting safety from procedure creation (only ~10% of the equation) to building a genuine safety culture (the remaining 90%). Procedures serve as static “maps,” but real incidents occur when dynamic shop-floor conditions (time pressure, missing tools, fatigue) cause workers to drift from them. The goal is moving employees from compliance (“I have to”) to commitment (“I want to”) through the human element.
  • Safety culture is defined as “how things are done when the boss isn’t watching” — the shared values, beliefs, and behaviors around risk. It requires three pillars: visible leadership commitment (walking the talk and investing in the physical environment), active employee engagement and ownership, and constant visual communication that reinforces safety at the point of work rather than just in meetings.
  • Human error is predictable and often systemic (fatigue and stress increase error risk fivefold; 70% of errors stem from processes rather than individuals). Normalization of deviance occurs when repeated shortcuts become the new normal. Effective solutions include positive reinforcement (three times more effective than fear-based messaging), proactive visual triggers (signs, floor markings, posters) that act as guardrails, and creating psychological safety so employees report near-misses and hazards without fear.
  • Strong safety cultures deliver measurable results, including up to 70% fewer incidents with high engagement, a 4-to-6x ROI on safety investments, and improved morale and retention. Practical steps include conducting visual audits, rotating messaging to prevent burnout, focusing on the critical 20% of behaviors that cause 80% of incidents, and celebrating good catches to build trust and continuous improvement. Visuals also serve as a universal language that overcomes literacy and language barriers.

Brady North America. 45 minute YouTube Video.

4 Ways Risk Managers Can Better Work with Underwriters and Why It Matters | Know Insurance. IRMI.

  •  Differentiate Your Risk: Risk managers should proactively communicate to underwriters why their firm is better than peers by highlighting how it exceeds minimum safety regulations and regulatory requirements, rather than just meeting them, to secure better rates and terms.
  • Build Long-Term Underwriter Relationships: Maintain ongoing, proactive relationships with underwriters through regular meetings and updates. Stay ahead of firm changes, regulatory shifts, and industry developments rather than treating insurance as a one-time transaction.
  • Know Your Audience: Tailor presentations to the specific underwriter, provide detailed financial information for D&O and surety underwriters, while focusing on relevant exposures and risks for property and liability underwriters. Briefly address financial stability, then quickly move to the concerns that matter most to them.
  • Get Involved Early in Major Changes: Involve your broker team early in mergers, acquisitions, and other significant events, even during draft purchase agreements, to identify synergies, address insurance provisions, and manage claims that may arise between signing and closing. This helps maximize savings and ensures smoother outcomes.

IRMI. 3 minute YouTube Video.

FMCSA SafeR Scores/ Dangers Of Hot Work/ HOT WORK Permit

How to find FMCSA safety scores on SAFER

  •  Learn how to find SMS safety scores on the FMCSA .gov website. 
  • Motor carrier safety ratings can be found using the SAFER website linked below. 
  • These are the kind of the major things that Insurnce Companies and Brokers will look for when they evaluating the trucking safety performance.
  • The profile of the company or anyone else's company you'll see the SMS Safety Measurment System score.
  • JD Logistics National. YouTube 4 Minutes

SAFER Company Snapshot on FMCSA

Dangers of Hot Work

 Lessons learned and shared in this Chemical Safety Board CSB video 'Dangers of Hot Work' can help sav lives and make you think about how to prevent injuries and fatalities in the welding, cutting, grinding, and hot work around potential flammables and combustibles, that your company does. 

  • Our families and friends are counting on a safe work environment.  You make the difference helping others go home safe.
  • The CSB has a number of incredibly good videos that tell the story of real tragic incidents in the US, and the lessons that can be learned.
  • The CSB has over 100 Free High Quality videos available online, on their Video Room page at csb.gov
  • CSB 14 minute YouTube Video.

HOT WORK PERMIT, From NFPA

  • This Hot Work Permit is required for any operation involving open flame or producing heat and/or sparks. 
  • Work includes, but is not limited to, welding, brazing, cutting, grinding, soldering, thawing pipe, torch-applied roofing, or chemical welding. 
  • Fill out and submit for a one-day permit.
  • https://www.nfpa.org/downloadable-resources/forms/hot-work-permit


  • Oregon OSHA 9 minute YouTube Video.


Machine Guarding/ Electrical Safety/Rack Inspection

Rockford Systems | Machine Safety Compliance 101 Webinar

  •  Machine safeguarding prevents thousands of serious injuries and deaths each year while avoiding top OSHA violations that cost millions in fines plus much higher indirect costs.
  • OSHA 1910.212 and the ANSI B11 series establish core requirements for protecting workers at the point of operation, nip points, rotating parts, and flying chips/sparks.
  • Practical methods include guards that meet the OUTA rule, light curtains with correct safety distance and function testing, two-hand controls, interlocks, pressure-sensitive mats, and machine-specific solutions for presses, grinders, lathes, and robot cells.
  • Best practices also cover NFPA 79 electrical standards (E-stops, dropout protection), danger signs with pictograms, regular testing, and resources for deeper training.
    Rockford Systems 65 minute YouTube Video.

Electrical Safety Basic Training for Non-Electricians

 This Schneider Electric video delivers essential electrical safety awareness training designed specifically for non-electricians working in industrial or commercial environments.

  • It stresses the importance of following safety regulations and basic precautions to prevent electrical fires, electrocution, and other serious workplace hazards.
  • Explains core electrical safety practices, including the correct use of protective equipment such as shock-proof boots and other safety gadgets when working near electrical systems.
  • Learn how Schneider Electric switches and devices help improve overall electrical safety, plus practical tips to protect themselves and their colleagues.

Schneider Electric. 10 minute YouTube Video.

What to Expect During a Pallet Rack Safety Inspection

 This video stresses the growing importance of warehouse rack safety inspections following a 23% increase in fatal injuries from 2020 to 2021.

  • It explains the key categories inspectors evaluate, how professionals identify safety risks, and why independent third-party inspections are essential for compliance and protection.
  • Viewers learn practical preparation tips, the green/yellow/red hazard coding system, how to address issues ranging from minor damage to serious violations, and ways to build a lasting safety culture.

The Lifting and Rigging Channel. 10 minute YouTube Video.

OSHA Forklift Etool -Powered Industrial Trucks

Ergonomics Success/ Combustible Dust/ Machinery Security

OSHA Ergonomics: History, Enforcement, and Success Stories

 Ergonomic injuries (MSDs) are cumulative soft-tissue damage (muscles, tendons, ligaments, spine) caused by awkward postures, forceful/repetitive motions, vibration, contact stress, and psychosocial factors; they account for roughly one-third of workplace injuries, cost ~$20 billion in direct medical expenses and up to $100 billion in indirect costs annually in the U.S., and can lead to chronic disability (e.g., herniated discs, rotator-cuff tears, carpal-tunnel syndrome).

  • OSHA’s enforcement approach relies on the General Duty Clause (Section 5(a)(1)) after Congress repealed the 2001 ergonomics standard; since 2001 OSHA has conducted ~7,100 ergonomics inspections and issued >1,100 hazard-alert letters (plus ~60 formal citations), focusing on high-risk sectors such as healthcare, warehousing, manufacturing, and meatpacking through national emphasis programs and complaint-driven inspections.
  • Landmark cases established key precedents: Beverly Enterprises (nursing-home chain) produced a corporate-wide settlement requiring mechanical lifts, training, and programs across 800 facilities; Pepperidge Farm yielded a $1.4 million willful citation for extreme lifting (later sustained) while showing that employers’ prior abatement efforts can limit citations for repetitive-motion hazards.
  • Three documented success stories illustrate dramatic results: Missouri Slope Lutheran Care Center cut MSD risk from 1-in-7 to 1-in-50, achieved EMR discounts of ~38 %, and earned VPP Star status via zero-lift policies and ceiling lifts; TitanX reduced DART 31 % and MSD-DART 48 % after an EHAL by adding lift assists and two-person rules; Ducommun eliminated severity rates (from 13+ to zero) by installing a hoist at a quench-tank workstation.

YouTube,  CORH & California Labor Lab 63 minutes.

OSHA Guidelines pdf. Ergonomics for the Prevention Musculoskeletal Disorders

Deadly Dust: Explosions at Didion Milling

On May 31, 2017, an initial combustible dust explosion inside milling equipment at the Didion Milling dry corn mill in Cambria, Wisconsin, triggered fires that propagated through process piping and secondary explosions throughout the facility, ultimately destroying the plant, killing 5 workers, and injuring all 19 employees on site.

  • The CSB investigation identified critical failures including the company’s failure to recognize that finely ground corn products and dust were combustible, absence of any dust hazard analyses (DHAs), and inadequate control of fugitive dust that fueled the devastating secondary explosions.
  • Weak process safety leadership and a poor safety culture allowed repeated smoldering fires and process upsets to be treated as normal, while the facility’s sanitation program (based on food-safety standards rather than combustible-dust hazards) left critical areas like dust collectors and overhead spaces uncleaned and unmonitored.
  • The CSB recommended stronger NFPA guidance (later addressed by the new NFPA 660 standard), a comprehensive process-safety leadership and combustible-dust management system at Didion, and once again urged OSHA to issue a broad combustible-dust standard covering all industries that handle such materials.

USCSB. 15 minute YouTube Video.

Research Security: Safeguarding America’s Critical and Emerging Technologies

 Safeguarding science is essential to national security, as adversarial nations use cyber espionage, intellectual property theft, and personal/professional connections to steal U.S. research and gain technological dominance.

  • These threats cause billions in economic losses, endanger national security, and undermine U.S. leadership in science and technology.
  • Research security serves as the first line of defense by protecting data, technology, and innovation from foreign interference and misuse.
  • NIST has developed a series of research security training videos to educate researchers on the risks and protective measures, enabling safer collaborative science.

NIST. 2 minute YouTube Video.

Economics of Manufacturing Machinery Maintenance NIST.AMS.100-34

Business Interuption/ Active Shooter/ DON'T BE ME

How to Conduct a Tabletop Exercise for Better Emergency Response

 This video explains what tabletop exercises are, why they benefit organizations, who should participate, and how to run them effectively.

  • Learn proven strategies to better prepare for threats, identify gaps in response plans, and align emergency teams on their roles.
  • Discover best practices for after-action reviews and reports to document lessons learned and build improvement plans.
  • Gain insights from Peter Steinfeld (AlertMedia) on assessing and strengthening emergency response plans through low-risk simulations.

AlertMedia 14 minute YouTube Video.

OSHA, Create Your Own Emergency Action Plan (EAP)

Active Shooter- Run, Hide, Fight (Updated 2025)

  •  Introduction & Context: Violent incidents can occur. Leadership prioritizes safety through planning, training, and partnerships, yet individuals must take personal responsibility by staying aware and prepared for active threats.
  • Run (Primary Option): The first and best response is to escape immediately, putting maximum distance between yourself and the attacker. Once safe, call 911 to alert law enforcement; help is en route, but immediate self-action is critical.
  • Hide (Secondary Option): If escape is impossible, barricade entry points, turn off lights, lock doors, silence phones, and stay quiet to avoid detection. Remain alert for emergency alerts while making it difficult for the threat to locate you.
  • Fight (Last Resort) & Community Preparedness: If the attacker approaches before help arrives, fight using any available objects as improvised weapons and find strength in numbers to survive. The video stresses that Run, Hide, Fight is not one-size-fits-all—assess your situation, report suspicious activity ("see something, say something"), know campus alert systems, participate in training, and view safety as a shared community responsibility.


 Louisiana Board of Regents,  YouTube, 7 minutes

‘DON'T BE ME’: ARC FLASH SURVIVOR SHARES ACCOUNT OF NEAR-DEATH INCIDENT

In 2009, Jason Brozen was severely injured when an arc flash occurred while he was performing work on an energized breaker at a hotel in Kansas. Without any personal protective equipment (PPE), the incident left Brozen, who at the time had more than 14 years of experience as a master electrician under his belt, with third-degree burns on his face and arms. He spent a week in a coma and two weeks in an intensive care unit.   

NFPA 9 minute YouTube Video.

PROPERTY RENEWALS/ ASSESS FIRE PROTECTION/ PROPERTY HAZARD

MASTERING PROPERTY RENEWALS

  •  Despite a softening property insurance market, securing favorable renewals requires comprehensive, data-driven risk management rather than relying on market trends alone.
  • Independent risk engineering and proactive loss control are essential for uncovering hidden hazards and enhancing submission quality to insurers. 
  • Proactive risk mitigation, supported by data, strengthens negotiations to secure improved coverage, better rates, and increased insurnce carrier capacity.
    TÜV SÜD 43 minute YouTube Video.

Fire Protection Engineering and Inspections

 Global Risk Impact: Explores how fire and explosions drive the top business losses worldwide, causing $1.2 billion in annual U.S. manufacturing damages. 

  • Underwriter Expectations: Explains why rising insurance rates and strict regulations demand detailed, data-driven fire risk management plans from brokers and risk managers.
  • Engineering Assessment Process:  Analyze process hazards, inspect equipment reliability, and verify sprinkler and alarm system mitigation capabilities.

TÜV SÜD 2 minute YouTube Video.

Property Loss Control: Identifying and assessing property hazards

  • Expert Property Assessment: Industry specialist Mike Herrmann shares advanced strategies to identify, evaluate, and mitigate critical structural and operational risks.
  • Proactive Hazard Mitigation: Learn actionable methods to assess vulnerabilities ranging from natural disasters and fire safety to day-to-day operational hazards.
  • Data-Driven Engineering: Discover how structured on-site surveys and quantitative analysis help calculate potential losses.
  • Insurance Renewal Leverage: Understand how high-quality risk reports build carrier confidence.

TÜV SÜD 3 minute YouTube Video.

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