Line 7 at Midwest Metal Products had a problem. Despite glove requirements and safety training, minor hand injuries were constant. Paper cuts from packaging. Abrasions from parts handling. Nicks from sheet metal edges. Nothing serious — but the cumulative cost in first aid time, workers' comp claims, and productivity loss was adding up.
"We were averaging six to eight recordable hand injuries per quarter," says Safety Manager Tom Kowalski. "Most were minor, but they still meant paperwork, potential OSHA issues, and workers who couldn't perform at 100%."
The Glove Paradox
The obvious solution — heavier gloves — created its own problems. Line 7 assembles precision components. Workers need to feel what they're doing. Heavy cut-resistant gloves killed the dexterity required for quality work.
"When we mandated heavier gloves, quality metrics dropped and cycle time increased," Tom explains. "Workers would remove them for delicate tasks. Then they'd get cut. We were stuck."
Targeted Protection
The solution came from a worker suggestion: self-adhering tape on specific vulnerable areas. Fingertips that contacted sharp edges. Knuckles that brushed against parts. Palms that gripped metal.
Unlike gloves, the tape could be applied exactly where needed and left off where dexterity was critical. Workers could customize their protection based on their specific tasks and their specific hands.
The Results
Line 7 went 90 days without a recordable hand injury — their longest streak in three years. Quality metrics returned to normal. Workers reported less hand fatigue at end of shift.
"It's not magic," Tom is quick to note. "It's just the right protection in the right places. Targeted instead of blanket. That made all the difference."