Manufacturing & Distribution

Three major causes of loss in the manufacturing and distribution industry are:

1. Overexertion involving outside sources (lifting/handling objects)
2. Falls on same level
3. Being struck by object or equipment

Understanding these trends allows for a focused analysis when evaluating an employer’s claim characteristics compared to industry peers.

1. Strains and Sprain Injuries

These are a leading cause of employee injuries, negatively impacting workers’ compensation costs. The solution is to complete a loss trend analysis to identify the number and source of losses associated with strains and sprain injuries. Analysis should include:

• Identifying the types and causes of losses by location and job function.
• Conducting a job hazard analysis to identify the root cause of losses.
• Ergonomics review to determine if physical changes to the workplace will minimize exposure (e.g., raising the height of a lift or automating the process).
• Use of wearable technology, sensors and guards to monitor and improve employee safety and prevent overexertion while performing certain tasks (e.g., human exoskeletons, vests). This technology also allows plant managers to review workflow and potential issues in real time, and implement risk management protocols.
• Assess the potential for job rotation to minimize repetitive stress claims.

2. Slips, Trips and Falls (STFs)

These incidents are a leading cause of employee injuries in industrial settings, resulting in higher workers’ compensation costs. The solution involves a comprehensive risk analysis to identify and address losses, including:

• Using analytics to create a heat map that identifies STF losses by location, cause (wet or oily floor), day, and month to determine any trends. USI also keys in on high foot traffic areas and extraordinary events at each of our client’s properties.
  • The results of the heat map will lead to a customized a risk control plan to address the findings, and focus on the loss/cost drivers that will mitigate and eliminate future claims.
• Usage of state-of-the-art security cameras with artificial intelligence in high-traffic and remote areas that send alerts when unusual behavior is detected.
• Improving worker safety and mitigating claims with wearable technology for employee/location tracking and fall detection.
• Using a nonslip polish on the floor and making sure maintenance is trained to apply the polish according to the manufacturer’s recommendations.
• Providing maintenance and housekeeping training to identify and clean surfaces immediately upon identifying a spill and reinforce safety initiatives.

3. Being Struck by Objects or Equipment

According to the U.S. Bureau of Labor Statistics, 20,480 manufacturing workers are injured annually after being struck by objects or equipment. The solution is to complete a risk assessment, analyzing historical loss data and workstation tasks to develop a customized plan focused on preventing or minimizing the frequency and severity of loss.

• Identifying locations and job functions along the process flow where struck-by injuries have occurred.
• Reviewing forklift operations and operator qualifications.
• Implementing engineering controls to include barriers, guards or shields.
• Conducting personal protection equipment assessments.
• Training employees.
• Addressing plant traffic layout.
• Assessing material storage.
• Reviewing material lifting/rigging procedures and inspections.

USI offers industry-leading risk management and insurance solutions that result in positive financial impact for a wide range of operations including plastics, metals, textiles, chemicals, electronics, energy products, food processing, and heavy industrial equipment. Our team advises clients with a comprehensive suite of solutions that address the most cost-effective program design.

Transportation

Three major causes of loss in the transportation industry are:

1. Overexertion involving outside sources (lifting/handling objects)
2. Falls on same level
3. Vehicle crashes

Understanding these trends allows for a focused analysis when evaluating an employer’s claim characteristics as compared to industry peers.

1. Strains and Sprain Injuries

Strains and sprains resulting from overexertion in lifting are a leading cause of employee injuries, negatively impacting workers’ compensation costs. The solution is to complete a loss trend analysis to identify the number and source of losses associated with strains and sprain injuries, which includes:

• Identifying and analyzing the types and causes of losses by location and job function.
• Conducting a job hazard analysis to identify the root cause of losses.
• Ergonomics review to determine if physical changes to the workplace will minimize exposure (e.g., raising the height of a lift or automating the process).
• Use of wearable technology, sensors and guards to monitor and improve employee safety and prevent overexertion while performing certain tasks (e.g., human exoskeletons, vests). This technology also allows managers to review workflow and potential issues in real time, and implement actional risk management protocols.
• Assess the potential for job rotation to minimize repetitive stress claims.

2. Slips, Trips and Falls (STFs)

Outside of motor vehicle collisions, STFs are a leading cause of driver injuries. These injuries can occur many ways, from entering or exiting the truck or trailer; performing tasks outside of the truck, such as pre/post trip inspections; managing fifth-wheels and landing gear; securing and tarping loads; and performing loading/unloading activities. Environmental conditions such as ice/snow and rain often increase driver risk for STFs.

The solution is a comprehensive risk analysis specific to STFs, resulting in customized and targeted risk control solutions for the specific loss causes identified in the analysis. Targeted solutions may include:

• Developing and implementing a stretch and flex program for all drivers.
• Implementing a safety shoe program that will provide proper shoes for the conditions drivers will encounter.
• Providing material handling equipment appropriate to operations.
• Developing and documenting specific safety rules associated with each outside activity.
• Developing and implementing a STF training program for all drivers.

3. Vehicle Crashes

Adverse auto liability claims have a direct impact on market access and pricing, as well as retained loss costs, heightening the need for robust and effective risk control strategies. Rising claim expense related to social inflation, tightened capacity, and collateral demands continue to challenge many organizations in terms of financial impact and work force stability. A proactive and measurable analysis can help mitigate future losses and in turn create positive economic results, improved productivity, employee retention and continued improvement.

In USI’s experience, the top 5 crash types for fleet operators (rear end, loss of control, lane change, intersection, and hit object) account for 66% of all reported crashes, and 85% of incurred claim costs. The solution involves a comprehensive risk analysis to determine the root cause of fleet losses, as well as potential exposures, including:

• Analyzing metrics (frequency, severity, etc.) to identify and prioritize corrective action.
• Customizing a fleet safety program that addresses any shortcomings in existing program, focusing on operational/fleet exposures.
• Completing a risk/gap analysis of current company safety policies, practices, procedures, training, documentation and record retention.
• Onboarding new drivers and providing ride-alongs with supervisors or designated lead drivers.
• Training drivers on cause and controls for preventing vehicle accidents (live/online).
• Using driver cams and pulse brake lights to minimize rear-end collisions.
• Rating drivers based on telematic performance — revoking driving privileges for poor drivers.
• Preventing unauthorized employees from using company or personal vehicles for business use.
• Inspecting vehicles on daily basis.

Construction

Four major causes of loss in the construction industry are:

1. Falls to lower level
2. Overexertion involving outside sources (lifting/handling objects)
3. Being struck by object or equipment
4. Falls on same level

1. Falls to Lower Level

Falls result in the most severe workers’ compensation incidents in the construction industry. The solution is to complete a site risk assessment and a job hazard analysis (JHA) to identify the primary loss drivers resulting in falls from heights, as well as a customized risk control program that includes:

• Analysis of the jobs most frequently involved in working from heights as well as training and protective equipment to those employees (hard hats, proper shoes, safety belts).
• Assessment of physical changes to the workplace to minimize exposure that may involve installing a fall protection system (railings, guards, etc.).
• Review of existing ladders and equipment to make sure they are in good condition and proper for the work.
• Ladder and platform training.
• Wearable technology and GPS monitoring devices that track the movement and location of an employee, and provide fall detection, improving employee safety.

2. Strains and Sprain Injuries

Strain and sprain injuries are a leading cause of disabling injuries, negatively impacting workers’ compensation costs in the construction industry. Typical exposures in the construction environment are: 

• Lifting and moving
• Reaching (overreaching) in awkward ways
• Using heavy tools and equipment
• The aging workforce

The resulting workers’ compensation claims lead to persistent insurance rate increases, decreased production efficiencies, low employee morale and impact on ability to competitively bid on new work. The solution is to complete a loss trend analysis to identify the number and source of losses associated with strains and sprain injuries, which includes:

• Identifying and analyzing the types and causes of losses by location and job function.
• Prioritizing corrective actions to prevent or reduce the potential for loss, which include:
  • Delivering materials close to where they will be used.
  • Storing materials off the ground.
  • Identifying weights of material and setting weight limits for items to be lifted without help.
  • Providing equipment or help for lifting and moving materials.
  • Making sure there are clear pathways for moving materials.
  • Using wearable technology, sensors and guards to monitor and improve employee safety and prevent overexertion while performing certain tasks. This technology also allows site managers to review workflow and potential issues in real-time and implement actionable risk management protocols.
  • Assessing the potential for job rotation to minimize repetitive stress claims.
  • Training on ergonomics and safe lifting.
  • Providing toolbox talks that promote safe lifting practices.
  • Developing work procedures unique to your business that are enforceable.

3. Being Struck by Objects or Equipment

According to the U.S. Bureau of Labor Statistics, 20,480 workers are injured annually after being struck by objects or equipment. The solution is to complete a risk assessment, analyzing the employer’s historical loss data and workstation tasks to develop a customized plan focused on preventing or minimizing the frequency and severity of loss.

• Identifying locations and job functions along the process flow where struck-by injuries have occurred.
• Reviewing forklift operations and operator qualifications.
• Engineering controls to include barriers, guards or shields.
• Conducting personal protection equipment assessments.
• Training employees (job specific, RMC online, small group).
• Addressing plant traffic layout.
• Assessing material storage.
• Reviewing material lifting/rigging procedures and inspections.

4. Slips, Trips, and Falls (STFs)

STFs are leading causes of injuries in the construction industry. They are frequently associated with soft tissue injuries (back injuries, twisted ankles and knee strains) that can be debilitating and costly. Environmental factors that are commonly associated with STFs are:

• Uneven ground that is too soft, too hard, wet, or muddy.
• Distractions or obstruction of view while manually carrying materials.
• Inadequate housekeeping.
• Fast-track, or meeting construction deadlines.

The solution involves a comprehensive risk analysis to identify and address losses, including:

• Assessing the usage of state-of-the-art security cameras with artificial intelligence in high-traffic and remote areas that send alerts when the system detects unusual behavior.
• Improving worker safety and mitigating claims with the use of wearable technology for employee/location tracking and fall detection.
• Performing a daily risk assessment to identify and remove STF hazards in high-traffic areas.
• Using proper communication channels to increase worker participation in identifying and eliminating hazardous conditions.
• Ensuring work areas and stairwells are properly illuminated.
• Using slip-resistant shoes to provide added protection.
• Ensuring workers are aware that running and horseplay are not permitted.
• Training on STF prevention.

USI delivers industry-leading solutions and services to general contractors, trade contractors, property owners, investors and construction professionals. Our in-depth expertise aligns with all phases of the construction process so we can protect your business and your bottom line from start to finish.

Real Estate

1. Slips, Trips and Falls (STFs)

These incidents plague real estate owners and property management firms as the number one liability claim, both in first-party workers’ compensation and third-party general liability. Inclement weather and heavy pedestrian foot traffic areas have an increase in frequency and severity. Direct causes of loss include:

• The procedures and products used to clean and maintain floor surfaces.
• Maintenance staff not having proper instruction and training in floor care.
• Failure to follow manufacturer’s directions when cleaning and applying a finish.

The solution is a comprehensive risk analysis to identify and address STF losses. A customized heat map can identify first- and third-party exposures and identify specific areas with adverse trends and opportunities for improvement.

The results of the heat map allow real estate companies to customize a risk control plan to address the findings and focus on those loss/cost drivers that will mitigate and eliminate future claims, such as:

• Slip/skid meters to perform a coefficient of friction (COF) analysis.
• Surface and/or non-slip cleanser, coating and/or buffing agent to bring the COF to desirable levels.
• Assessment of state-of-the-art security cameras with artificial intelligence in high-traffic and remote areas that sends alerts when the system detects unusual behavior.
• Improved worker safety and mitigate claims with the use of wearable technology for employee/location tracking and fall detection.
• Training of foodservice, maintenance and housekeeping staff regarding the importance of quick response to spills and maintaining treated surface(s) according to manufacturer’s recommendations.
• Slip-resistant shoes.
• Increased awareness through social media messaging, weekly safety talks and interactions with employees.

2. Hazard Communication

Real estate and property management firms use a wide range of hazardous chemicals and toxic substances during routine maintenance tasks. Improper use, storage and lack of training creates an increase in risks and health hazards (such as irritation, sensitization, and carcinogenicity) and physical hazards (such as flammability, corrosion, and explosion). The solution is a risk assessment to identify and address exposure for worker contact with chemicals. The process includes:

• Creating a site-specific risk assessment to identify and catalog chemicals and quantity on hand and the areas where they are used, handled and stored or where chemical contact could occur.
• Prioritizing usage and location of chemicals to create an action plan on proper storage and training.
• Developing a plan focused on:
  • Eliminating the need for worker contact with chemicals.
  • Using automated equipment to minimize the number of employees having contact with a specific chemical.
  • Training employees and management team members on cause and controls to prevent these events.
  • Using personal protective equipment to reduce contact and exposure with a chemical; goggles, masks, ventilators, etc.
  • Keeping eye-wash and wash bins close by for emergency first-aid.

3. Injury and Illness

For real estate organizations a specific injury and illness prevention program (IIPP) is statutorily required in many states, and failure to have an effective IIPP can result in significant fines. Companies should schedule an analysis of their safety programs to ensure they meet and support any statutory IIPP and strongly promote their safety cultures in the following key areas:

• Management leadership — Support and assign responsibility for compliance and oversight of the program.
• Employee participation — Engage workers and allow their participation in the development of the program.
• Hazard identification — Audit for safety hazards and document the process.
• Prevention and controls — Assure proper safety controls are put in place.
• Education — Train employees on proper safety and injury and illness prevention.
• Program evaluation and improvement — Review and update the IIPP to reflect any changes in the work environment, ensuring continuous improvement.

The adoption and implementation of an IIPP that targets key risk and safety areas can lower the potential of high severity claims and reduce injuries, illnesses, and fatalities. Real estate companies can experience many financial benefits of a safer and healthier workplace, including: reduction in risk, claims and premium; lower mod factors (20% to 35%) resulting in reduced premium; and reduction of indirect costs, such as loss of productivity, recruiting and training.