Workplace Safety Trends

Evolving Technology Protects Workers ‘24/7’

The Internet of Things is fueling “the next industrial revolution” and is poised to make a significant impact on workplace safety.
By: | January 25, 2016 • 4 min read

A worker in a high risk area gets an alert: three feet away from him and one foot above there is a brace that is about to give way, putting the worker and his colleagues at risk. Because he received the information when he did, the workers were able to take steps to protect themselves and avoid damage to the facility.

The technology isn’t necessarily new. But what is new is the connectivity of the worker to the Internet with data passing immediately to supervisors who can analyze the information and provide feedback back to the worker.

It’s being called ‘the next industrial revolution.’ It’s enabled by IoT — the Internet of Things. And it’s saving companies an average $200,000 to $300,000, depending on the size of the facility.

“This convergence of industrial systems that exist and marrying them with advanced computer capabilities, low cost sensors — we have a new wave of going back into the industrial settings and improving efficiencies for the operation but also worker safety,” said Bridget Karlin, managing director of the IoT Strategy and Office in the Internet of Things Group at Intel. “That’s essentially what’s happening.”

Intel has partnered with Honeywell to create a personal connected safety solution for industrial workers. The prototype was recently introduced at an annual showcase demonstrating innovative IoT hardware and software.

How It Works

The Honeywell Connected Worker solution begins with ‘connecting’ a worker from head to toe with various WiFi and communication technologies. Basically, the worker’s standard operating gear is equipped with sensors and other technologies.

“They are being integrated into everyday tools the industrial worker already uses and is now being enabled with these wearable technologies and becoming part of it,” Karlin explained. “The old hard hat becomes a smart helmet; the vest you wear to climb a pole is outfitted with technology, helping you stay safer.”

Smart watches worn by the worker can capture pulse and heart rate information. A ‘smart’ body activity belt includes various sensors, including ones that can understand gestures.

“So [the worker] could wave his arm in a certain way, spell a letter with his arm, and it could mean ‘man down,’” she said. “We have these wearable technologies that are basically collecting data that is being transmitted through a mobile hub he is also wearing. Your phone can act as a mobile hub … collecting data, sending it to the Internet, and that data is getting analyzed for things like what the worker is doing.”

Depending on the industry and type of facility, the sensors could be incorporated in self-contained breathing apparatus and a heart rate monitor. Information about the worker’s heart rate, posture, motion, and potential exposure to toxic gas can be transmitted.

“We are connecting different devices and getting the data into actionable form, so the worker is protected 24/7,” said Prabhu Soundarrajan, Global Business Development director at Honeywell analytics. “When a worker is doing jobs with varying levels of risk, we really use technology to put more eyes on the problem. Somebody in a control room can see if there is a panic alarm, a gas alarm, or an injury … We are able to really help mitigate a lot of the risk for the worker.”


Honeywell plans to begin using the system for gas inspectors in the near future. Beyond that, the company believes it can be used just about anywhere.

“We really see this market evolving and connectivity driving real time data and providing safety compliance and productivity,” Soundarrajan said. According to the Gartner Group, network-connected devices will soar to 26 billion by 2020.

Factory workers for example, could don the wearable devices to enable bidirectional data between the worker and supervisor. “So if he is going to bring a line down, what else should he be looking at?” Karlin said. “Or, ‘you were supposed to do this particular repair, but it doesn’t need it.’”

Mine workers, health and safety workers, even office workers could take advantage of the technology, the companies say. “Even a worker for Amazon who is fulfilling shipments,” Karlin said.


While neither company would release specific cost figures, officials said they are trying to make it affordable. “We’ve changed our model to be extremely scalable,” Soundarrajan said. “Our goal is to really make it easy to adopt in terms of switching costs … If the technology is too expensive, they won’t use it.”

Soundarrajan said the system can be a huge cost saver for companies. “We’ve done some analysis in the market,” he said. “Each [savings] at an average sized plant [would be] $200,000 to $300,000, depending on the plant site.

Some companies may find they don’t need to make too many changes to use the system. “Many of these industrial settings already have sensors in place and haven’t really utilized the data available,” Karlin said. “Now we can send the data from the worker, so you have a fusion of data and now we are taking advantage of things already in place.”

Nancy Grover is the president of NMG Consulting and the Editor of Workers' Compensation Report, a publication of our parent company, LRP Publications. She can be reached at [email protected]

More from Risk & Insurance

More from Risk & Insurance

4 Companies That Rocked It by Treating Injured Workers as Equals; Not Adversaries

The 2018 Teddy Award winners built their programs around people, not claims, and offer proof that a worker-centric approach is a smarter way to operate.
By: | October 30, 2018 • 3 min read

Across the workers’ compensation industry, the concept of a worker advocacy model has been around for a while, but has only seen notable adoption in recent years.

Even among those not adopting a formal advocacy approach, mindsets are shifting. Formerly claims-centric programs are becoming worker-centric and it’s a win all around: better outcomes; greater productivity; safer, healthier employees and a stronger bottom line.


That’s what you’ll see in this month’s issue of Risk & Insurance® when you read the profiles of the four recipients of the 2018 Theodore Roosevelt Workers’ Compensation and Disability Management Award, sponsored by PMA Companies. These four programs put workers front and center in everything they do.

“We were focused on building up a program with an eye on our partner experience. Cost was at the bottom of the list. Doing a better job by our partners was at the top,” said Steve Legg, director of risk management for Starbucks.

Starbucks put claims reporting in the hands of its partners, an exemplary act of trust. The coffee company also put itself in workers’ shoes to identify and remove points of friction.

That led to a call center run by Starbucks’ TPA and a dedicated telephonic case management team so that partners can speak to a live person without the frustration of ‘phone tag’ and unanswered questions.

“We were focused on building up a program with an eye on our partner experience. Cost was at the bottom of the list. Doing a better job by our partners was at the top.” — Steve Legg, director of risk management, Starbucks

Starbucks also implemented direct deposit for lost-time pay, eliminating stressful wait times for injured partners, and allowing them to focus on healing.

For Starbucks, as for all of the 2018 Teddy Award winners, the approach is netting measurable results. With higher partner satisfaction, it has seen a 50 percent decrease in litigation.

Teddy winner Main Line Health (MLH) adopted worker advocacy in a way that goes far beyond claims.

Employees who identify and report safety hazards can take credit for their actions by sending out a formal “Employee Safety Message” to nearly 11,000 mailboxes across the organization.

“The recognition is pretty cool,” said Steve Besack, system director, claims management and workers’ compensation for the health system.

MLH also takes a non-adversarial approach to workers with repeat injuries, seeing them as a resource for identifying areas of improvement.

“When you look at ‘repeat offenders’ in an unconventional way, they’re a great asset to the program, not a liability,” said Mike Miller, manager, workers’ compensation and employee safety for MLH.

Teddy winner Monmouth County, N.J. utilizes high-tech motion capture technology to reduce the chance of placing new hires in jobs that are likely to hurt them.

Monmouth County also adopted numerous wellness initiatives that help workers manage their weight and improve their wellbeing overall.

“You should see the looks on their faces when their cholesterol is down, they’ve lost weight and their blood sugar is better. We’ve had people lose 30 and 40 pounds,” said William McGuane, the county’s manager of benefits and workers’ compensation.


Do these sound like minor program elements? The math says otherwise: Claims severity has plunged from $5.5 million in 2009 to $1.3 million in 2017.

At the University of Pennsylvania, putting workers first means getting out from behind the desk and finding out what each one of them is tasked with, day in, day out — and looking for ways to make each of those tasks safer.

Regular observations across the sprawling campus have resulted in a phenomenal number of process and equipment changes that seem simple on their own, but in combination have created a substantially safer, healthier campus and improved employee morale.

UPenn’s workers’ comp costs, in the seven-digit figures in 2009, have been virtually cut in half.

Risk & Insurance® is proud to honor the work of these four organizations. We hope their stories inspire other organizations to be true partners with the employees they depend on. &

Michelle Kerr is associate editor of Risk & Insurance. She can be reached at [email protected]