Overconfidence / recklessness
Many accidents happen because you do a routine task "off the cuff". The classic example is the dilution of acids or the dissolution of bases. In most cases, exothermic reactions occur here. The mixture heats up strongly, splashes and can cause chemical burns to the skin or - even worse - to the eyes. Newly trained employees tend to be cautious at the beginning, which can lead to uncertainty (next point). However, this rarely leads to accidents. After a certain point, recklessness/overconfidence sets in and the aforementioned accidents occur, not only when handling chemicals.
Insecurity
Like overconfidence, insecurity is to a certain extent a question of character. However, it occurs more frequently in activities that involve a certain level of risk and where there has been insufficient instruction or simply a lack of a healthy routine. Most people are familiar with the latter, especially after taking their driving test. Hardly any practical experience, possibly a new, unfamiliar vehicle and driving alone for the first time. Uncertainty inhibits thought processes to an extreme degree, which leads to inadequate reactions, but above all to mistakes that you hardly think possible. In the workplace, this means Instruct employees properly and make them feel safe. Only allow employees to carry out delicate tasks once they are sufficiently confident and have a healthy routine.
Carelessness
It is due to the zeitgeist of mobile devices that accident rates are increasing due to carelessness. Not only, but above all, safety-related tasks require full concentration. This is not only due to distraction by electronic devices, but also includes conversations, tiredness, distracting thoughts and other factors. Carelessness can not only lead to accidents, but also to economic damage. Think of excessive dosages or - privately - a transposed number on a bank transfer.
Ignorance
Ignorance does not protect against damage - in electroplating, instruction is the be-all and end-all. The question "why" may also be askedMostaccidents at work that occur due to ignorance are caused by deficiencies in instruction or training. There are two sides to this point. On the one hand, there is the instructor or trainer, if there is one at all, who provides insufficient information to carry out the work satisfactorily from every point of view. It is not enough just to tell them how to do something, but also why it is done that way and what to look out for.
A simple example from the kitchen: for someone who has never cooked before, the information "fry the onions" is not enough to achieve a satisfactory result. It may lead to a positive result, but if you provide the basic conditions (stove, pan, oil, onions) and further information (cut of the onion, temperature, quantity and time), the chance of a good result is much higher.
"Dilute the sulphuric acid 1:1." can be said to someone who has already done this several times and knows the dangers. Otherwise not.
The other side is the instructed person. Employees who tend to be overconfident tend to ask fewer questions and take it for granted that they will complete the task to their satisfaction.
Tip:
If you have the feeling that you have not been fully instructed, at least ask what you need to be aware of when carrying out the task. Don't be afraid to ask "why" sometimes. It is better to do things consciously right than unconsciously wrong.
Reflexes / helper syndrome
The classic is the falling knife. You are standing in the kitchen and instead of taking a step back, you try to catch it with your foot. As, unlike a sandwich, the knife doesn't fall on the "wrong" side, you quickly realize that your reflex wasn't the best. There's not much you can do in situations like this. A reflex is a reflex. All you can do is visualize the correct course of action.
It's similar with helper syndrome. The brain likes to say goodbye when you feel the need to help or avert danger. If a coil weighing several tons starts rolling in the electroplating line, it doesn't help anyone to try to stop it with your body. The same applies to often desperate attempts to extinguish a small fire .
Tip:
If you are not absolutely sure that you know what you are doing, it is better not to do anything. At least you won't make things worse.
Technical problems
There is often nothing you can do about technical problems. Or so you think. What you can do, however, is to double-check sensitive equipment, such as temperature sensors. Plus plausibility checks and sufficient maintenance cycles.
A healthy distrust of technology never hurts. Just because a displayed value corresponds to expectations does not mean it is correct. This applies to level indicators, temperature measurements, pH value measurements and other parameters. Process and/or safety-related technology must be checked regularly. In the case of very sensitive devices, even devices that are in order tend to be replaced after a certain cycle because the risk of a defect is too high.
General tip:
It is a law of nature that no animal behaves stupidly in its natural environment. This law can also be applied to humans, especially in the workplace. For new employees, the workplace is an unnatural environment at the beginning and they behave accordingly. If you are new yourself, you should be aware of this and not feel bad if you feel insecure. As an experienced employee and especially as a manager, you should make sure that the new workplace becomes a natural environment for the employee as quickly as possible.
This article is a lesson from the online course "Occupational safety in electroplating plants" on our website "Galvanotechnik for you!". The following explanations and the course are intended to help electroplating companies provide their employees with comprehensive training in occupational safety. After answering the exercise questions, course participants receive a certificate as proof. In order to effectively prevent accidents, the general causes that lead to an accident must be known. This applies not only to work, but also to private life. The following causes can therefore also be applied to other areas of life, such as road traffic.
* = "Personal injury before property damage" means as much as: Personal injury has a higher priority and must be averted before property damage.
