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Accidents in Manufacturing Plants: 10 Hidden Costs


rf 26537851 injuryclaimCould they be double what you think?

There’s an accident on your factory floor. Your first thought is for worker safety, of course.  Not far behind is determining the cost, and it may be more than you think. There are hidden costs beyond the injured worker’s lost time and medical expenses. Here are 10.

  1. Co-workers’ lost time. Who helped the injured worker? Took him for medical assistance? That doesn’t take into account the time spent retelling the story at the water cooler.
  2. Insurance costs. Your rates may go up; your deductibles may increase. The effect can be on your health coverage or, if there’s equipment damage, your property insurance as well.
  3. Lost efficiency in a work group. Take out one member, and a whole work area may be shut down or run inefficiently with back-up labor.
  4. Supervisor’s lost time. There’s injury care, incident reports, and scrambling to get the workflow restarted. 
  5. New employee hiring. You may need a temporary or permanent replacement worker. The time to find, hire and train can be substantial.
  6. Damaged equipment. Replacements or repairs, and downtime while you wait for them, can be costly.
  7. Lost productivity. If there’s a work interruption or equipment is down, production is down.
  8. Dissatisfied customers. With a key employee off the job, even for a short time, quality may suffer. Orders may not get filled on time.
  9. Lost sales. Customer dissatisfaction eventually works its way to the bottom line.
  10. Cash flow disruption. Lost sales and unexpected expenses play havoc with operating budgets, which impacts your ability to run and grow your business.

The solution? Make safety your goal every day. Use assessments, processes, proper PPE, training and monitoring. It’s the right thing to do for your workforce. And it’s a smart business decision.


There's a workplace eye injury every 43 seconds


Don't miss this Workplace Safety News article

Workplace HR What's the impact of workplace eye injuries? The editors of Workplace Safety News asked Defog It's Jodi Groh to write an article on the facts and solutions. We thank them for the opportunity to share this important information and invite you to do the same.


Why workforce diversity is a red flag for safety eyewear compliance


One-size-fits-all approach puts workers at risk.

The growing diversity in America’s workforce gender and ethnicity creates a new challenge in assuring safety eyewear provides proper protection for every worker. Significant differences in height, width, or location of cheekbones, nose bridges, and ears, as well as overall head size and shape, need to be considered for proper fit,  according to a recent article in Occupational Safety and Health magazine. What are the key facts to consider for updating the traditional one-size-fits-all approach?

  • Women are 47 percent of the labor force, growing to 51 percent by woman in safety glasses2018. The number of Hispanics will more than double from 11 percent in 2000 to 24 percent in 2050, and Asians, now 5 percent, will increase to 11 percent in the same period.
  • Up to 85 percent of workers will have a good fit right out of the box. For the rest, adjustability feature, like temples or nosepieces, can help.
  • It can be valuable to fully fit-test eyewear, not just distribute it. 90% of eye injuries can be prevented with properly fitted eyewear.   
  • A hypothetical example from the International Safety Equipment Association shows how an eye injury that cost a company nearly $1 million could have been prevented with a $5 pair of safety glasses.
  • A secure, gap-free fit can be prone to fogging. Download research-based best practices to address the problem in Seven Tips for Workplace Eye Safety on the Defog It website.

Is computer eye strain blurring workplace productivity?


Workplace Eye Wellness Month focuses on the problem for 70% of adults.

Nearly 7 in 10 adults suffer dry eyes, blurred vision and headaches, the most common symptoms of digital eye strain, according to a recent report by The Vision Council. While most people know the trouble caused by long hours using computers, smartphones and other electronics, 41% have never tried – or don’t know how – to reduce the problems. 

Make March − Workplace Eye Wellness Month – your opportunity to help prevent problems that can plague workers and hinder productivity. Prevent Blindness, the founders of the observance, suggests a number of tips, including these:

  • Position your screen 20-26 inches away from your eyes and a little bit computer eye strainbelow eye level.
  • Adjust the text size on the screen to a comfortable level.
  • Place a document holder next to your computer. Position it close enough to prevent the constant change of your eye focus.
  • Cut glare by adjusting lighting or adding a glare filter over the screen. 
  • Take a 20-20-20 break:  every 20 minutes, take a 20-second break and look at something 20 feet away.

Can you pass this Workplace Safety Quiz?

Workplace Eye Wellness Month should also be on your calendar for a safety eyewear program for workers who require regular protection. Prevent Blindness has a 10-question Workplace Safety Quiz to get you started.  

Respirators and fogging issues…new OSHA new rules


Are you ready for new OSHA crystal silica exposure rules?

Changes aim to protect 2.2 million workers, save hundreds of lives

OSHA has recently proposed new standards for worker exposure to crystalline silica. Breathingrespirator in the dust particles can cause silicosis, an incurable lung disease, as well as lung cancer, COPD, and kidney disease. 

Why the change? The methods of measuring exposure and the threshold exposure levels date back 40 years, and new data suggests they don’t properly protect workers.  These changes will expand protection to cover more at-risk workers.

Who’s affected? OSHA lists all these industries as having silica risk: asphalt roofing materials, concrete products, cut stone, dental laboratories, foundries, jewelry, porcelain enameling, pottery, railroads, ready-mix concrete, shipyards, structural clay products, and support activities for oil and gas operations.


Construction and fracking are likely to see the most changes

Of the 2.2 million exposed workers, about 1.85 million are in construction and related fields. While common sense precautions have long been in place, more efforts are likely to be mandatory. On the building site, there’s going to be more oversight of workers who are cutting, grinding, crushing, or drilling into concrete, masonry, tile and rock.  


Hydraulic fracturing, or fracking, which requires drilling into shale and rock to tap into oil and gas deposits, is also under scrutiny. It is, quite literally, a new industry, so oversight protocols are just being developed.


What are the changes? Additional respirators and more.

The new OSHA rules include a number of changes. It starts with changes in the way exposure is measured, which is likely to have the effect of reducing limits. The bottom line? More workers will need protection, including: 

  • Limiting access to areas of exposure
  • Dust controls – like specialized vacuum ventilation systems, water sprays or enclosure
  • Respirators when dust controls don’t provide adequate protection
  • Training for workers and records of exposure


Adding respirators? Test Defog It anti-fog for fog prevention.describe the image

It’s no secret fogging is an issue – both for respirators and eyewear worn under it. The new workers OSHA will be covering, oil and gas and construction workers, are at particular risk because they’re outdoors in heat, cold, changing temperatures and high humidity.


Request a Defog It anti-fog cloth sample today

5 fogging danger zonesTest Defog It in your toughest workplace conditions. Defog It is the first choice in workplaces around the world – see what it can do for you. And download our free whitepaper, Five Fogging Danger Zones, to help you pinpoint and address problems in your workplace.


Follow the new rules and more at the very thorough OSHA crystalline silica portal.   

An Interview with Krish Rao, new President of Nanofilm


Krish RaoFind out about the future, his plans, and one thing he’ll never change.

Dr. Krish Rao took the reins as Nanofilm’s President this past December, but he brings a long history of success from his previous role as the company’s Vice President of Technology and Commercialization. He’s been the motivating force behind the introduction of new lens care and anti-fog products and the company’s nano-coatings for the past seven years. His prior background includes a variety of organizations, both large and small, with a track record of successfully managing diverse functions and rebuilding organizations for customer focus and innovation.  


What do you envision for Nanofilm in the next year? Next 3-5 years? 

Firstly, I want to reassure all our customers that our commitment to delivering Quality and Service remains unchanged. For the past two decades, Nanofilm has worked hard to deliver value and innovation in all our products, and we shall continue to find new ways to exceed expectations.
Nanofilm has consistently led in our industry with significant investments in R&D, manufacturing capabilities and our strength in artwork and design. We will continue to invest in these areas to bring game-changing products to re-energize and refresh our product lines. Furthermore, we expect to bring exciting new nanotechnologies to market in the next 5 years. All of these will directly benefit our customers and their customers.
In our manufacturing operations, we are implementing programs to enhance production capacities and broaden our ability to offer new product formats. This is something that we do constantly.   

You’re making a point to meet with more customers in your new role, is that right? 

I think it’s important to take the opportunity to meet – or meet again – with customers in this new role. I want to shake their hands, say thank you, and find out how Nanofilm can do more for them.

How do you see the global marketplace for Nanofilm?

We are already a global player. We’re planning to take our products further into Asia, Southeast Asia, the Middle East and Africa. In many ways the markets in those regions are at the stage the U.S. and European markets were 10 years ago and are ready for professional lens care products. We are confident that Nanofilm’s product technology and expertise in packaging design will be greatly appreciated by customers there. At the same time we will continue our focus in Europe and South America to forge new partnerships.

What are three phrases that describe the Nanofilm you envision? 

A leader through technology and customer focus.
Constantly evolving and adapting. 

A challenging yet fun place to work. I have been lucky that in my career, in all my jobs, I’ve always jumped out of bed each morning eager to get to work, because it’s been fun and rewarding.


What about the phrase you’ve been using around the office: Work smart, work together?

That’s the way any company succeeds. It’s the way Nanofilm works, and I want us to remember it and continue to reinforce it. It’s the way Nanofilm is always going to stay a leader – working as a team to provide an unmatched pool of talent and skills to our customers. By working smarter, we minimize time and efforts to reach our goals.  


Where do you find ideas or inspiration for new products and product improvements? 

Great product ideas start with customers’ needs articulated in many different ways. But the reality is that some product ideas can and should be generated internally within the company.  All ideas at some stage or the other have to be vetted by the customer before we go too far down the path. Over the years I’ve learned to take customers’ inputs expressed in their language, including some of the intangibles, truly understand the requirements, and then internalize it into terms that are tangible and easily recognized by the organization. Sometimes you might end up with something different from where you thought you started, but in the end, it delights the customer.
Good product ideas can also come from failure. You start by going after some set of attributes, but end up with very different characteristics that deliver even better performance. 

What are three phrases that describe you? 

I tend to be direct and frank in all my dealings. You get what you see. 

I truly believe I’m always learning…every single day, whether at work or at home. 

I enjoy humor. I feel I have a good sense of humor and employ it at work whenever appropriate. In addition to breaking the ice, it relaxes people and puts them at ease, and can defuse an awkward or tense moment. Most importantly, it makes us smile, which is good for health!


Do you have a favorite quote or guiding principal? 

I have two. 

One is from Gandhi: “Live as if you were to die tomorrow and learn as if you were to live forever.”

The other is by Thomas Jefferson: “I find that the harder I work, the more luck I seem to have.”

Do you have a favorite hobby?

I love to golf. I’m terrible at it, but love to play. I haven’t played famous courses, but I’ve played many courses. I always carry my clubs in car, so I’m ready to play if an opportunity comes up. 

You travel a good bit for business and for pleasure.  Do you have a favorite destination?

I love to travel and sightsee. My most recent game-viewing trip to Tanzania is now my all-time favorite. It was incredible to observe many different animals, both predators and prey, at such close proximity and in such abundance all around us!


Can we set up an auto ship program for you?


Help! I’m out of Defog It.

Set up an auto-ship program so you’re never out of inventory.

helpWe’re getting last-minute calls from customers fogged up by the freaky late winter weather. Surprise snowstorms and sub-zero temps in one part of the country…summery heat waves in others. Now the real change of season is coming on. And fog may be the only reliable prediction for an in-like-a-lion-and-out-like-a-lamb Spring. 

We’re happy to send you rush shipments, but an auto-ship program could simplify your life.  Monthly, quarterly, biannually – whatever you need to protect your workers vision and safety.

Just contact Gina Montello, Defog It Specialist, to work out a plan at 888-ENDS FOG or

Workplace Safety Magazine includes Defog It tips for a safer 2014


Workplace Safety Magazine spotlights vision protection.
Includes Defog It tips for a safer 2014.

A tip of the hardhat to Workplace Safety Magazine for sharing a few of our tips on including vision safety in your workplace New Year’s resolutions. We’re proud to be featured in this new monthly publication that has a lot of useful content for Safety and HR professionals. They post some helpful safety videos on their website, too.

Why not download our full list of 10 New Year’s Eye Health Resolutions for work and home? It’s still not too late to see a healthier 2014!

Screen shot 2014 02 10 at 3.25

Why do people love Defog It?


Read our Top Ten Testimonials

For work, play and everyday, people reach for Defog It anti-fog for fog-free vision. From military personnel around the globe to manufacturing plants in Australia to folks in all 50 states. Why do they love it? Read their own words – we couldn’t have said it better ourselves.

    “Heat and humidity are usually the problem. In the summer it’ll get up to 100% humidity describe the imagesometimes. I received word this morning that the [Defog It anti fog] wipes came in, and everyone is using them. And they really work great.”
    — Josh Hollingshead, Project Cost Controller, San Juan, Construction

    “Defog It is truly amazing. I selected some of the more arduous tasks and skeptical workers for a trial, and they were amazed at how effective the Defog It wipes actually keep the glasses clear…or only momentary fogging occurs.”
    — Peter Whelan, Workplace Health and Safety Officer, Isis Sugar Company, Childers, Australia

     “PECO Energy Company uses the Clarity Defog It towelettes on our safety glasses and shields for the purpose of preventing fogging, and has been pleased with the performance of the product.”
    — Mark M. Green, Sr. Electric Methods Specialist, PECO Pennsylvania, electric & natural gas utility

    "I used one cloth yesterday at a surface open pit dimension stone quarry in Georgia. One cloth for five men, and they too became convinced. The temp was 92 degrees with high humidity. Hours later, I went back and checked on them. They were very pleased with the fact they did not have to remove their glasses repeatedly on account of the constant fogging of the lenses."
    — Jerry Daniels, OSHA general safety and MSHA mine safety training consultant

    “I tested these out in the extreme conditions. I work in a freezer, going in and out, and my Defog It Resealable Clothglasses are fairly thick so they fog up easily and these wipes worked great.”                                                      
    — Zachary A Bracken, Edinburg, Virginia

     “I have been using Defog It over the last few weeks on a half-dozen different face shields, and we're amazed at how well it works.”
    — WebBikeWorld Motorcycle Magazine

    “I believe I can patrol in some of the worst conditions with goggles now.”
    — Ski Patrol Officer, Helena, Montana

    “I wear glasses and have a problem with fog-overs when hunting. With this product I was able to hunt without constantly wiping my glasses, therefore I highly recommend this product to anyone who hunts with glasses.”
    — Dwight Burdine, hunter

    “I ride a bike to work and in the morning my glasses fog up at every stop. But with this defog on my glasses I can see very clear at all times. I trust this product on all eyewear.”
    — Kevin Mendoza, cyclist

    “BMX racing requires quick reflexes. Fogged goggles reduce (drastically) the field of vision. [Defog It anti-fog towelettes] work perfectly, with no issues. Normally we use the wipes when we arrive at the track, and haven’t had any need to re-apply during races or practices.” 
    — Cory Taylor, BMX Bike champ

    Nanofilm announces Krish Rao as new President of Nanofilm


    KRAONanofilm has named Krish Rao as President of the company.  He succeeds Scott Rickert, company founder, who retains his role as Chief Executive Officer. 

    Dr. Rao has been Nanofilm’s Vice President of Technology since joining the organization in 2006.  “Krish Rao has a track record of product development success at Nanofilm,” said Rickert. “His ability to blend research and development expertise with an understanding of the realities of commercialization makes him ideal for a leadership position for a future of growth.”

    “With a portfolio of products enabled by nanotechnology and an expanding global reach, it’s an exciting time to for me to lead the Nanofilm team and help continue the momentum,” noted Rao.  

    Rao brings over thirty years’ experience in new product development and commercialization in fibers, plastics, and film industries, for diverse end use market such as aerospace, automotive, power tools and construction.  His previous experience encompasses rebuilding organizations for customer focus and speed and managing diverse functions such as R&D, Manufacturing, Quality Control, Technical Service and Materials Management groups.   The holder of four patents and author of a variety of technical publications, Dr. Rao holds a BS in Chemical Engineering from the Indian Institute of Technology, Masters Degrees in both Chemical Engineering and Engineering Administration, and a Ph.D., from the University of Utah in Materials Science and Engineering.

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