A Comprehensive Model of Manufacturing and Production Safety Culture

This thesis focuses on developing a comprehensive model for manufacturing and production safety culture, a critical aspect of modern industries. It addresses the necessity of safety culture in these sectors, highlighting past incidents and the loss of valuable workforce due to inadequate safety measures. The research includes data gathered from primary and secondary sources, including a survey conducted at Alive and Wells, interviews with managers, supervisors, and labor in-charge, and a review of company documents related to past accidents. The study analyzes the collected data to provide insights and recommendations for improving safety culture, aiming to reduce workplace accidents and enhance the overall safety performance of manufacturing and production companies. The thesis covers various aspects such as research background, literature review, research methodology, data analysis, discussions, recommendations, and conclusions, providing a thorough examination of the topic.

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DEVELOPING A COMPREHENSIVE
MODEL OF MANUFACTURING AND
PRODUCTION SAFETY CULTURE

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Executive Summary
The thesis is base on the topic of “Developing a comprehensive model of manufacturing and
production safety culture”. The concept is quite familiar in the modern industries that
manufactured the various products without the people cannot think of running their lives in the
recent times. The earlier studies show the necessity of the safety culture in the production as well
as the manufacturing sector. The former researches describe how the industry has lost the
valuable workforce in earlier days. The study below provides an analysis on addressing the
issues related to workers safety and avoiding unnecessary incidents. Therefore, many measures
have taken in order to control the accidents in the workplace. As a result, the disasters have come
under control however; there are some loopholes in the strategies. Undoubtedly, this negligence
often causes the accidents in the manufacturing industry in recent days.
In order to gather a proper knowledge regarding the safety culture in the production or
manufacturing industry as well as increase the awareness for the issue among the authority and
the labors of the various companies the researcher has conducted the research work. For the
accomplishment of the study the individual has gather enough data from the primary as well as
the secondary source. The individual has chosen a company named Alive and Wells in order to
conduct the survey among the workers of the organization. The person also had taken interview
of the manager, supervisor, as well as the labor in charge to get their opinion regarding the safety
issue inside the company. The researcher also has studied various documents as well as the
register of the company to get the meticulous report of earlier accidents in the company. After
that the researcher has evaluated and analysis the data and come to the conclusion.

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Acknowledgements
I would like to acknowledge the dedication, patience, and hard work to all my teachers and
professors and other supporting staff to carry on the research and helped me to complete the
paper. I would thankful to all the members and respected teachers with their constant effort and
support it became easier for me to complete the study. It would be glad to mention their name
and even if I missed out some of the dignitary’s name, I would be apologies for the same. In
perusing of the research, I would like to thanks all the staff, members, individuals, managers,
employees of different organization from where the data have collected. Without their help it
would be impossible for me to complete the research. Without their sheer patience and period it
would not have been able to bring the accuracy that I hoped for and ultimately fulfilled. Last but
not the least the coordinators and the co- workers with whom I was conducting my research. I am
proud that I had an excellent opportunity to do this wonderful research. I would also want to
thanks to fellow mates and friends without their help it is not possible at all. Lastly, I would also
like to express my gratitude towards my friends and fellow classmates who have helped me with
multiple times to sort all kinds of major and minor issues or problems.

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Table of Contents
CHAPTER 1: INTRODUCTION....................................................................................................6
Research Background..................................................................................................................7
Rationale of the study..................................................................................................................8
What is the research issue?......................................................................................................8
Why is it an issue?...................................................................................................................9
Why it is an issue now?...........................................................................................................9
What could research says light on?.......................................................................................10
Research aim..............................................................................................................................10
Project Brief...............................................................................................................................11
Research Accomplishment........................................................................................................12
Task Description........................................................................................................................13
Research Hypotheses.................................................................................................................13
Problem Statement.....................................................................................................................15
Potential Benefit of the Research:.............................................................................................16
CHAPTER 2: LITERATURE REVIEW.......................................................................................17
Introduction................................................................................................................................17
Previous Literature.....................................................................................................................18
Preliminary study of safety culture in a manufacturing industry..........................................18
The Role of Leader Influence Tactics and Safety Climate in Engaging Employees' Safety
Participation...........................................................................................................................19
2.1.1 Planning and implementing improvement policies of safety culture in the organization
...............................................................................................................................................20
2.1.2 To identify the challenges faced by the organization in maintaining safety culture in
production and manufacturing setting...................................................................................21
2.1.3 To evaluate the resource requirements of safety culture programs and to fulfill such
requirements..........................................................................................................................23
2.1.4 To make people aware of the need and importance of health and safety policies........24
2.1.5 To explore cooperation and coordination between workers and employers................26
Summary....................................................................................................................................27
Conceptual framework...............................................................................................................28
CHAPTER 3 RESEARCH METHODOLOGY............................................................................29

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Survey questions:...................................................................................................................30
Research Paradigm....................................................................................................................33
Research approach.....................................................................................................................33
Research Theory........................................................................................................................34
Case Study 1:.............................................................................................................................35
Research Data Analysis:............................................................................................................36
Interview Data...........................................................................................................................37
CHAPTER 4: DATA ANALYSIS................................................................................................39
Project Approaches....................................................................................................................40
Case study 2...............................................................................................................................43
The Success Rate of Emerson at Plant Site...........................................................................45
Case study 3...............................................................................................................................46
Case Study 4..............................................................................................................................49
Experimental Methods...................................................................................................................52
Manufacturing Analytics...........................................................................................................52
Sampling Technique..................................................................................................................53
Ethical Consideration.................................................................................................................54
Research Limitations.....................................................................................................................54
Survey Results...............................................................................................................................56
Quantitative Analysis Results....................................................................................................63
Time Table.................................................................................................................................67
CHAPTER 5: DISCUSSION........................................................................................................69
CHAPTER 6: RECOMMENDATIONS.......................................................................................71
CHAPTER 7: CONCLUSION......................................................................................................73
Bibliography..................................................................................................................................75
Appendices....................................................................................................................................84
Maps, Tables and Pictures.........................................................................................................85

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CHAPTER 1: INTRODUCTION
The research on development on comprehensive model of manufacturing production safety
culture highlights on the fact, and it is one of the identical aspects of developing both the parts
that is one, which highlights the information on safety as well as manufacturing production. In
other words, we can also come to a point that it is totally base on the ethics of research where the
basic idea of the implication of workplace safety has upper edge than the manufacturing and
production. We have to make an effort on the fact that the work culture safety is the main
concern throughout the research paper rather than manufacturing of production. Yes, it is
oblivious to the fact that the production related to manufacturing materials has also discussed in
this thesis paper but more focus will done on the production safety in work culture. As from
now on, we will discuss about the details of the facts and each aspect with minute detail relevant
to topic. In the process of discussing about the facts and findings we will be coming across many
case studies, many data analysis, charts, grant charts, figures, as well as supportive documents
that need to provide will be attached as we proceed on throughout the research.
The accident in the workplace is not familiar to the worker. It can happen in every type of
organization. According to the various studies in every fifteen seconds, at least one hundred and
sixty workers are injured and one dies in several unfortunate incidents in the workplaces. In the
same way around six hundred and three hundred workers dies in the work related calamity in
every day. The data undoubtedly reveal the fact that manufacturing industries are losing a huge
number of the human resources in every second because of the poor safety culture inside the
organization. Obviously, it brings an adverse repercussion on the production as well as the
reputation of a company. Therefore, it is quintessential to investigate in the matter and try to
control this situation so that no unfortunate incident in the workplace can take the toll of
workers’ lives.

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Research Background
In modern society, people have become more concern about safety culture in their workplace.
IAEA or the International Atomic Energy first introduced the concept of safety culture in the
year 1986. It was just after the catastrophe in Chernobyl1. The accident took place in a nuclear
power plant. It is believe that the cause of the disaster laid in the error of the rector process test.
Because of this of this unfortunate incident around thirty labors’s lost, their lives and one of the
rectors had destroyed. In addition, many people were severely injured. While analyzing the
causes of this baffling catastrophe the International Atomic Energy concluded that the
mismanagement as well as the poor safety culture of the power station is the main reason of such
unfortunate disaster. Similarly, another two accidents had occurred because of the inappropriate
as well as insufficient safety culture in the workplace. One of those was in King’s Cross in the
year 1987 and other was in Piper Alpha Oil factory in the year 19882.
The above incidents undoubtedly proved that safety culture in the utmost important while
constructing a manufacturing plant or other organization. The history of manufacturing industry
has established its importance. It is notice that some firm already has the safety plant however; it
does not support the safety performance of the company. Safety performance as well as safety
culture is two different issues. Hence, every organization needs to have safety culture to get the
better safety performance3.
Several researches in past few decades show the importance of the safety culture inside an
organization. However, very few researchers were able to define the term clearly. According to
most of the concepts, the work culture is base on the features of the work, connection,
1 Vedant Singh and Anita Verma, "A Review, Simple Meta-Analysis And Future Directions Of Safety
Climate Research In Manufacturing Organizations" [2018] International Journal of Occupational Safety and
Ergonomics.
2 David A. Hofmann, Michael J. Burke and Dov Zohar, "100 Years Of Occupational Safety Research: From
Basic Protections And Work Analysis To A Multilevel View Of Workplace Safety And Risk." (2017) 102(3)
Journal of Applied Psychology.
3 Heng Li et al, "Proactive Behavior-Based Safety Management For Construction Safety Improvement"
(2015) 75 Safety Science.

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management procedure and at last the physical environment4. As per the PERKESO, in the year
2014 the incidents of work related accident has increased from around 55,000 to 61500 in
Australia in the year 20125. The studies shows that around 105 labors in every ten thousand
labors are involved with the disaster that take place in their work place. Therefore, it has become
a provocative question in the modern civilization.
Rationale of the study
What is the research issue?
A research issue is a declaration about particular concerned area, an improved condition, an
elimination of difficulty, and problems or problematic queries, which exist, in Scholarly
literature in theories, where points needs to be discussed with deliberate and meaningful
investigation and understanding. In some cases, the research issues are poised in a framework of
a question pattern. An issue in research is not focus on a particular state of performing or doing
something, or not offering a valueless or unfruitful question, it is all about broad proposition or
presentation of valuable questionnaire. The purposes of discussing the issues related to the safety
culture in an industry are:
 Introduction of the importance of topic needs to be studies by the reader: The
orientation or significance of the study and the questionnaire on research or
hypothetical approach towards the research.
 Problems based on particular context needs to be properly place: The parameter
need to investigate is properly define.
 Framework is being implemented for results and reporting: Explanation of the
findings and necessary guidelines required to conduct studies. Those are the
issues we faced while conducting the research on developing a comprehensive
model of manufacturing and production safety culture in workplace or an
environment.
4 David Yoon Kin Tong et al, "Leadership Empowerment Behaviour On Safety Officer And Safety
Teamwork In Manufacturing Industry" (2015) 72 Safety Science.
5 G. Reniers, "On The Future Of Safety In The Manufacturing Industry" (2017) 13 Procedia Manufacturing.

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Why is it an issue?
The basic ethical guidelines required for research is the daily work requirements, the dignified
version of topic or subject needs to be protect, and information that needs to be publicized about
the research information. The three basic value added system need to be focus when an employee
is conducting the research. The dilemmas, panic tension are three major areas of concern when
the employee or the researchers worked on certain research related to production safety and
manufacture of the industry6. The definition of safety is the implication of having a free
environment from hazards, health concerns and injuries, whereas on other hand production can
be related to safety management like prevention of accident and taking or measuring control over
things that can be implemented in an organization. It is one of the most important components to
be deal with very care that is safety and management, which ultimately leads to production and
those same results to growth of an organization. It is an activity of efficient utilization of
resources. The control of issues is required for the production safety management and which will
ultimately leads to the prospect and growth of an industry7. It is need to be treating efficiently.
Why it is an issue now?
The reason of the issues is one of the common aspects that needs to identify first and then needs
to be treated. It may occur due to various factors, which may be other than production safety
also. It may be due to environment depending on cultural barrier, social aspect, pragmatic issues
and many more areas needs to be highlighted .The main areas needs to get focused is the ability
to identify the process and finding the reason behind it that if it happens for certain cause then
why it is taking place on so frequent basis. The work related accidents and the barriers needs to
be curtail in production safety management. It strikes the balance between the materials related
to machinery and human based equipments. The quality of production hugely depends on the
safety management and on the basis of that the issues needs to be get resolved as early as
possible 8. The factors that affect the issues are discussed above which may be on some cases
cannot be identified properly or meaningfully it is not at all possible to be identified hence the
6 Gaganpreetkaur et al., Gaganpreetkaur et al., "Concern Of Construction Industry Towards Occupational
Safety And Health Issues" (2018) 8(3) International Journal of Mechanical and Production Engineering Research
and Development.
7 Sylwia Gierej, "Big Data In The Industry - Overview Of Selected Issues" (2017) 25(4) Management
Systems in Production Engineering.
8 Peter Moss, "Why Can’T We Get Beyond Quality?" (2016) 17(1) Contemporary Issues in Early
Childhood.

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issues prevails for a prolonged amount of time. The problems lay in detection, which needs a
research and study of doing so.
What could research says light on?
The research aims at bringing or sharing the ideas related to the production safety and
management of the industry. It pours some showers on the fact and aspect about the vitality and
awareness of employees in an organization9. In one of the case studies we have mentioned about
the fact and the source based on the farming company Alive and Well where we have discussed
about certain points of the organization that are required to get improved regarding safety
culture. The study reveals more on the maintaining of the scenario of work culture, which is one
of the imperative factors related to the organizational progress including health and hazards.
Moreover, it is based on finding that barriers like production on safety affect the manufacturing
process also. It highlights the true enigma of beauty about the observation based not only on
safety culture but also on the workplace environment as well as manufacturing unit. It put a light
on ever ending dilemma between workers safety culture and the true essence of health concerns
of the employees. The research highlights on the fact of objectives of safe production and
manufacturing of objectives of safe production and manufacturing of certain material. It creates
or strikes the significant balance between environment and production process.
Research aim
The vision of the research is quite clear. The researcher has conducted the research in order to
figure out the amount of lose as well as the injuries that take place in the manufacturing unit of
various organization. Secondly, the individual wanted to assess the quality of the safety culture
in a firm10. The person also aimed to evaluate the opinion of the management team of the
production and management industry regarding to the safety features of several companies.
Another vision of the research was to increase awareness for the safety culture in the work place
so that the possibility of the accident can be control. It is obvious that the awareness regarding
the safety culture will enhance the productivity and such situation will lead the company to the
way of increasing the profit. Therefore, mention was another goal of conducting the research
work.
9 Sang-Dong Lee, "Awareness Of Disaster Among Service Employees: A Case Of Hotel Employees In
Korea" (2015) 11(10) Crisis and Emergency Management.
10 Radosandław Wolniak and Marcin Olkiewicz, "The Relations Between Safety Culture And Quality
Culture" (2019) 1(1) System Safety: Human - Technical Facility - Environment.

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On the contrary, the researchers had a humanitarian vision behind the study. As per the earlier
discussion, it is clear that accidents in the workplace had taken a great toll of lives of the workers
who were not only valuable for their companies but also for their families. As a result of the
unfortunate death of the employees the companies has to face severe loss as it does not only lose
it precious human resource but also it has to take the great financial burden because of the
compensation that the company needs to give the affected families in order to provide monetary
supports. On the other hand, the families of the dead or injured worker have to face a lot of
adverse financial situation because of the sudden disaster11. It is neither true that nor monetary
help can compensate the lives of the beloved person whom their families loss for ever. Hence, it
was one of the aims of the researcher to put a restraint on the accident of the various workplace
especially on the production as well as the manufacturing companies.
Project Brief
In order to conduct the research the researcher has made a clear plan of the entire thesis or the
project brief so that the individual did not need to face problem to continue the task. This
The project brief is plan in succession of the following task:
● At first, the researcher has given a specific topic and then the person approved the
proposal. In this case, the individual has provided a topic “Developing a comprehensive
model of manufacturing and production safety culture”.
● Then the individual selected a manufacturing company named Alive and Wells to run the
research project.
● Then the researcher collected the secondary data in order to acquire enough knowledge to
write the literature review on the safety culture in the manufacture industry12.
● Thereafter the individual identified the methodology of the research.
● After that the researcher talks to the workers as well as take interviews of the managers,
supervisor, labor in charge to accumulate the quantitative as well as the qualitative data
respectably 13.
● There after the researcher start analyzing the data in order to conclude.
11 Hardy Johnson and Brian Roseman, "ODD LOT ORDER AGGRESSIVENESS AND STEALTH
TRADING" (2017) 40(2) Journal of Financial Research.
12 Dennis Bakir, Tobias Feickert and Robin Bakir, "Smart Data Hub: Retrofit Solution To Acquire Process-
Inherent Knowledge" (2017) 11 Procedia Manufacturing.
13 Sheryl A. McCurdy and Michael W. Ross, "Qualitative Data Are Not Just Quantitative Data With Text But
Data With Context: On The Dangers Of Sharing Some Qualitative Data: Comment On Dubois Et Al. (2018)."
(2018) 5(3) Qualitative Psychology.

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● Next, the individual figured out the key findings of the entire research work.
● After that, the person builds his perception on the safety culture of the production and the
manufacturing sector.
● In the next level, the researcher prepared some recommendation based on the perception
of the study for the improvement of the company’s safety culture.
● At last, the researcher submitted the entire thesis to his professor.
Research Accomplishment
The above research illustrates that many elements are related in the safety culture of the
production as well as the manufacturing industry. These elements are often known as ‘safety
culture aspect’ or ‘safety climate aspect’14. The researcher has discussed the total few elements
that are intertwine with the safety culture of the workplace of manufacturing and production
industry. Those aspects are management strategy, communication in the workplace, working
environment, procedure of conducting the specific production as well as the practice of miss
reporting of the several disasters or the accident.
● The researcher came to know that management of the Alive and Wells are quite aware of
the safety culture inside the company. They have a plan to buy the highly equipped
machineries so that the workers need not to take risk of the lives while operating the
manufacturing procedure15.
● The supervisors or the labor in charges regularly talks to the workers in order to figure
out the safety requirement of the manufacturing unit. They also respect to the suggestion
provided by the workers.
● The management always encourages their workers to use the tools and the machineries so
that unfortunate incident can take place inside the manufacturing sector of the company.
Task Description
The researcher has conducted the research inside the manufacturing sector of the company
named Alive and Wells in Australia. The individual has chosen the working hours in weekdays
to continue the survey in order to collect data regarding the research work. In this research, the
14 Gabriel Raviv, Aviad Shapira and Barak Fishbain, "AHP-Based Analysis Of The Risk Potential Of Safety
Incidents: Case Study Of Cranes In The Construction Industry" (2017) 91 Safety Science.
15 Anass Cherrafi et al, "The Integration Of Lean Manufacturing, Six Sigma And Sustainability: A Literature
Review And Future Research Directions For Developing A Specific Model" (2016) 139 Journal of Cleaner
Production.