Workplace Safety as an Afterthought: A Risk You Can’t Afford
Workplace Safety as an Afterthought: A Risk You Can’t Afford
A Forewarning:
This article will likely rouse some while getting on others’ nerves. That’s the point. Because when it comes to safety in machinery, too many companies still view it as optional, or worse, as an afterthought.
Machine Safety: Let’s Take It Back
It was 1969 and times were good. People believed accidents didn’t happen if you “just didn’t do stupid things.” Then came 1970. Enter OSHA.
The Occupational Safety and Health Administration (OSHA) was formed to address rising injury and death rates on the job by establishing and enforcing federal safety standards across U.S. workplaces. Signed into law by President Richard Nixon on December 29, 1970, OSHA set out to ensure safe and healthy working conditions for all American workers. It provided enforceable standards, training, and support for states, ultimately building a culture of safety.
And it worked. Since OSHA’s inception, workplace incident rates have dropped dramatically, from 10.9 cases per 100 employees in 1972 to 2.8 cases per 100 employees in 2018.
Today’s Safety Standards
Fast forward to today. While safety has advanced in leaps and bounds, many of the systems built in OSHA’s early era are still running. In some ways, that’s a testament to the durability of those machines. But longevity doesn’t always equal safety.
Too often, I see facilities where safety is treated as an afterthought. The mindset is: “It’s been this way for years, why change it?”
That’s not a strategy. It’s gambling. Sure, the equipment may have run for decades without issue. But those years represent nothing more than luck. One wrong move, one accident, is all it takes to turn catastrophic.
Hold Your Vendors Accountable
What’s worse than old equipment lacking safety standards? Brand new equipment being purchased today that still fails to comply.
If that hits a nerve with you, good. This isn’t about blame; it’s about accountability. Safety is a continuous improvement process. Saying a machine was “designed 25 years ago and never changed” or that it’s “grandfathered in” is an absurd excuse in 2025.
Take automobiles, for example. In the 1970s, cars were made of solid steel. They were tanks. When crashes happened, though, the results were violent and often deadly. Over the years, automakers have relentlessly redesigned their vehicles with crumple zones, airbags, and reinforced cabins to save lives. The same mentality should apply to machine safety.
If you’re evaluating new equipment, don’t be afraid to ask tough questions. A vendor brushes safety off? Consider it a red flag. If there’s a lack of care, look for an alternative supplier. At the end of the day, you are responsible for the safety of your personnel.
The Cost Myth: Save Now, Pay Later
I often hear: “Safety costs too much.” Or, “It’s an expensive add-on.”
That mindset is dangerous.
The money you think you’re saving today will almost always cost you more later. Why? Because retrofitting safety into equipment after the fact is complex and expensive. It often requires:
- Mechanical redesign and fabrication
- Electrical and control system overhauls
- Installation and commissioning downtime
Take the example of a standard PLC vs. a safety PLC. Choosing the cheaper option on Day 1 might save you $1,200 upfront. But eventually, you’ll still need the safety PLC, meaning you’ve now paid for two. The math just doesn’t add up.
How We Help: Education and Knowledge Are Key
At Cleveland Automation Systems™, we find that many customers simply aren’t aware of today’s industrial safety standards. That’s not negligence, it’s a knowledge gap. Our role is to bridge that gap with education and support.
We work alongside our clients to:
- Educate teams on OSHA compliance, RIA, and ANSI standards
- Conduct risk assessments on existing equipment
- Pinpoint vulnerabilities and map out improvements
- Implement upgrades and retrofits with full-service solutions
Our process goes beyond advice. We stay engaged from planning through physical installation and commissioning. The goal is always the same: empower companies to make informed, proactive decisions about workplace safety automation.
The Bottom Line on Workplace Safety
Treating safety as an afterthought is not just risky, it’s unsustainable. Whether it’s outdated machinery or brand new equipment that doesn’t meet the mark, ignoring safety standards is a gamble no business can afford to take.
Prioritize safety today, or you’ll pay for it tomorrow.
If you’re unsure where your facility stands, or if you have questions about how to evaluate and improve your systems, reach out to us. Our team is here to help you navigate safety standards, assess your equipment, and implement solutions that protect both your people and your bottom line.
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About the Author: Rylan Pyciak
Rylan Pyciak, CEO of Cleveland Automation Systems™, is a Systems and Control Engineering graduate from Case Western Reserve University. With expertise in PLCs, robotics, and industrial engineering, Rylan leads CAS in delivering innovative automation solutions. Passionate about mentoring future trades professionals, he combines technical knowledge with a commitment to fostering sustainable growth in manufacturing.