Manufacturing & Materials
safety Services
Keep Production Moving While Keeping Workers Safe
Comprehensive safety, logistics, and project turnaround services for steel, automotive, pharmaceutical, and materials manufacturing operations.
Manufacturing Challenges
Manufacturing environments demand constant vigilance. From molten metal in steel plants to precision assembly in automotive facilities to sterile processing in pharmaceutical manufacturing, each brings unique challenges. The pressure is relentless. Production demands never stop.
Downtime costs range from $50,000 to $250,000+ per hour. Equipment must run reliably and quality standards must be maintained. Workers must stay safe while margins remain tight.
Downtime costs $50K-$250K+ hourly.
One unplanned shutdown costs more than annual safety program budgets.
Steel
Manufacturing
Molten metal operations create extreme hazards requiring specialized expertise. Heavy equipment and material handling risks are constant. Confined space work in furnaces and vessels demands rigorous oversight. Around-the-clock production requires 24/7 safety coverage. Turnaround costs can reach $10-50M+ with zero margin for delays.
Automotive
Manufacturing
Complex automation and robotics create sophisticated safety challenges. High-speed production lines demand flawless safety execution. Model changeovers require extensive contractor coordination. Line downtime during changeovers can cost millions. Maintaining quality and safety at production rates creates constant pressure.
Pharmaceutical
Manufacturing
GMP compliance during construction and maintenance is non-negotiable. Cleanroom contamination could ruin entire production batches. FDA inspections scrutinize every safety and quality procedure. Process safety for chemical synthesis requires specialized expertise. Any deviation from validated processes creates regulatory risk.
Our Manufacturing Experience
OnPoint was built supporting manufacturing operations. We've worked in every type of facility across every segment for 35+ years.
Our manufacturing industry experience spans steel production, automotive assembly, pharmaceutical manufacturing, chemical processing, food and beverage, paper and pulp, consumer goods, and plastics manufacturing.
We've managed hundreds of turnarounds and outages. We've supported sites from 100 to 2,500+ employees. Long-term partnerships with Fortune 500 manufacturers. Experience in both union and non-union environments.
Comprehensive Manufacturing Solutions
Manufacturing Safety Services
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Routine OperationsPrevent production shutdowns from safety incidents. Embedded professionals manage day-to-day hazards, so your
operations team focuses on throughput. -
Process Safety ManagementAvoid OSHA PSM violations that could shut down operations. Expert program support keeps covered processes
compliant without burdening production management. -
Specialized Manufacturing SafetyControl hazards unique to your processes. Molten metal expertise for steel. Robotic safety for automotive. GMP
compliance for pharma.
Industrial Plant Safety
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Site Safety LeadershipMaintain consistent safety across all shifts. Full-time advisors provide 24/7 coverage, so production never operates
without safety leadership. -
Occupational HealthReduce workers' compensation costs by 15-25%. On-site clinics treat injuries immediately, speed recovery, and lower claim expenses.
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Emergency PreparednessRespond to incidents in seconds, not minutes. Fire brigade support and emergency planning minimize damage when
incidents occur.
Manufacturing Logistics
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Materials ManagementEliminate maintenance delays and increased costs from missing parts. Warehouse management ensures critical spares
are always available when equipment needs repair. -
Production SupportKeep production lines fed without interruption. Raw material coordination and just-in-time delivery prevent costly line stoppages.
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Facility LogisticsMaintain plant efficiency with comprehensive support. Housekeeping programs and contractor coordination eliminate
distractions from production operations.
Plant Turnaround Services
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Pre-Turnaround PlanningComplete turnarounds on schedule without extending downtime. Comprehensive planning and scheduling identifies risks
early and ensures readiness before shutdown. -
Turnaround ExecutionDeploy 50-250+ professionals to execute safely at speed. Safety teams, WatchPoint technology, engineered ventilation,
and rescue teams enable efficient confined space work.
Technology for
Manufacturing
WatchPoint confined space monitoring enables multiple simultaneous entries during turnarounds. Engineered ventilation systems with HEPA filtration reduce exposures. Climate control improves worker comfort. SmartVent monitoring ensures optimal performance. TrackPoint materials tracking prevents lost parts and digital permitting streamlines approvals.
PROVEN RESULTS
FCC Turnaround Confined
Space Excellence
Challenge
- Control hexavalent chromium exposure in confined spaces during hot work on stainless and chrome steel.
- Enable simultaneous and continuous work while downgrading PPE requirements if feasible.
OnPoint Solution
- Engineered ventilation system designed for both general and local exhaust.
- Dust filtration and air conditioning for worker comfort.
- Ventilation technicians monitored performance, calculated air change rates, flow rates, and volumes continuously.
Results
CrVI exposure reduced from 300.5 µg/m³ to 10.9 µg/m³ (28X reduction)
Exposures well within 10x protection factor of half-face HEPA filter respirator
Multiple crafts able to enter vessels during hot work
Project finished at least two days ahead of critical path
"Overall schedule impact of using OnPoint with enhanced worker efficiency I estimate to be at least two days off of critical path."
Recent Project Experience
OnPoint has successfully deployed safety teams on major projects including:
250+
safety, logistics, WatchPoint, workforce transportation, materials management
Baton Rouge, LA
250+
safety and logistics, permit writers, safety advisors
Lemont, IL
250+
safety services, execution coordinators, materials management
Billings, MT
200+
safety and logistics, ventilation, materials management
Corpus Christi, TX
125+
WatchPoint, ventilation, safety and logistics, workforce transportation
Pascagoula, MS
100+
safety and logistics, execution coordinators, workforce transportation
Martinez, CA
Why Manufacturers
Choose OnPoint
Manufacturing Expertise
We understand process safety and production demands from decades of experience.
Turnaround Excellence
Proven track record on hundreds of turnarounds. We plan, execute, and complete safely and on schedule.
Scalability
From daily operations to 250+ person mobilizations. Consistent performance regardless of team size.
Technology Leadership
WatchPoint, TrackPoint, SmartVent provide capabilities traditional contractors can’t match.
Regulatory Expertise
Deep knowledge of PSM, OSHA, EPA, and industry-specific standards.
Integration Advantage
Safety plus logistics plus coordination eliminates gaps.
Partnership Approach
Long-term relationships and continuous improvement focus.
NEXT STEPS
Ready to Transform
Manufacturing Safety?
Your manufacturing operations need safety that protects production and profitability. Schedule a comprehensive manufacturing safety assessment. We'll evaluate your operations and develop a customized approach to reduce costs and complete turnarounds on time.
