Operating a manufacturing facility across multiple shifts introduces unique challenges for environmental, health, and safety (EHS) management. National data underscores the stakes: manufacturing has one of the highest rates of non-fatal injuries in private industry 3.2 cases per 100 full-time workers in 2022, totaling over 396,800 incidents (Employer-Reported Workplace Injuries and Illnesses, 2023).

A major contributor to these elevated risks is worker fatigue, especially during evening and night shifts. Injury rates during evening shifts run 18 percent higher, and night shift injuries are 30 percent more likely than those on day shifts. Moreover, 12-hour shifts increase injury risk by 37 percent compared to shorter shifts (Long Work Hours, Extended or Irregular Shifts, and Worker Fatigue, n.d.).

Communication and accountability gaps often appear between shifts, leading to unaddressed hazards. OSHA’s Safety and Health Program Management Guidelines emphasize comprehensive frameworks that prioritize leadership commitment, worker engagement, and continual evaluation (OSHA Safety and Health Program Management Guidelines, 2016).

For facilities using contractors or multiple employers on-site, OSHA’s Multi-Employer Citation Policy states that all employers may be held responsible for safety violations, regardless of who created the hazard, unless roles and responsibilities are clearly defined (Understanding OSHA construction standards for multi-employer jobsites, 2021).

Ergonomic issues, machine hazards, and mental fatigue are prominent in multi-shift operations. Repetitive strain injuries, slips, trips, and falls are frequently reported, especially in facilities without round-the-clock supervision or consistent safety messaging (About Ergonomics and Work-Related Musculoskeletal Disorders,2024).

To address these challenges, Key Safety LLC offers targeted services. Our Document Development for Start-up Projects ensures shift-specific safety protocols are embedded from project initiation. Service on Demand enables flexible training during second and third shifts. And our Regular Consultation Service includes fatigue-risk audits, EHS document reviews, and compliance updates aligned with OSHA’s evolving recordkeeping rules (OSHA’s New Era: Regulatory Shifts, Compliance Pressures and the Role of Technology, 2025).

To reduce risk, OSHA recommends limiting shifts to 8 hours and mandating rest breaks during extended or high-stress operations (Extended/Unusual Work Shifts Guide, n.d.). When shifts are longer, extra vigilance in hazard assessments, proper documentation, and consistent cross-shift safety briefings become essential.

Ultimately, successful EHS performance in multi-shift manufacturing requires continuous hazard prevention, fatigue mitigation, and management commitment. Key Safety LLC is here to help you meet those needs, across every shift, every day.

References

Bureau of Labor Statistics. (2023). Employer-reported workplace injuries and illnesses – 2023. U.S. Department of Labor. https://www.bls.gov/news.release/pdf/osh.pdf

National Institute for Occupational Safety and Health. (2024). About Ergonomics and Work-Related Musculoskeletal Disorders. Centers for Disease Control and Prevention. https://www.cdc.gov/niosh/ergonomics/about/index.html

Occupational Safety and Health Administration. (2016). OSHA Safety and Health Program Management Guidelines. U.S. Department of Labor. https://www.osha.gov/sites/default/files/SHPM_guidelines.pdf

Occupational Safety and Health Administration. (n.d.). Long Work Hours, Extended or Irregular Shifts, and Worker Fatigue. https://www.osha.gov/worker-fatigue/hazards

Occupational Safety and Health Administration. (n.d.). Extended/unusual work shifts. https://www.osha.gov/emergency-preparedness/guides/extended-unusual-work-shifts

Sodales Solutions. (2025). OSHA’s new era: Regulatory shifts, compliance pressures, and the role of technology. https://www.sodalessolutions.com/oshas-new-era-regulatory-shifts-compliance-pressures-and-the-role-of-technology/

Vector Solutions. (2021). Understanding OSHA regulations for multi-employer jobsites. https://www.vectorsolutions.com/resources/blogs/understanding-osha-regulations-for-multi-employer-jobsites/