Case Study

Near-miss reporting scaled across automated machining lines

An automotive component manufacturer replaced manual near-miss reporting, siloed observations, and inconsistent audit closure tracking with mobile capture, enterprise safety alerts, and centralised governance.

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Multi-plant
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Heavy equipment
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6 min read
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Client Highlights

Check Icon Modules: Incident Management, Walkthrough Inspection, Enterprise Safety Alerts
Check Icon Use Case: Near-miss culture + cross-plant learning + consistent closure
Check Icon Outcome: Higher near-miss volume + lower incident rate + fewer repeats

Executive Summary

The Problem

  • Behaviour observations existed but not analysed
  • Near-miss reporting was weak
  • Safety alerts and lessons learned weren’t shared

What Changed

  • Integrated BBS + incidents + walkthrough inspections
  • Mobile near-miss capture to remove reporting friction
  • Enterprise safety alert broadcasting + recommendation distribution

What Improved

  • 72% increase in near-miss reporting volume
  • 36% reduction in recordable incident rate
  • 49% faster incident investigation completion time

The Challenge

1
Weak near-miss culture: Reporting friction meant fewer signals from the floor.
2
Siloed observations: Behaviour observations were captured but not used to drive action consistently.
3
Cross-plant learning gaps: Alerts and lessons didn’t travel reliably between locations.
4
Inconsistent closure: Audit findings tracked locally made closure discipline uneven.

Context & Constraints

Operating environment Automated machining
Process risk High
Standardisation need Cross-plant consistency
Mobile adoption For low-friction reporting

What We Implemented

Deploying a standardized, integrated safety environment across all active operational sites.

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Behaviour Observations + Near Miss

Configured for: More signals from the floor, captured fast and routed correctly.

Key Workflow Controls

  • Check Icon One-tap near-miss capture with guided categories
  • Check Icon Behaviour observation templates with frequency targets
  • Check Icon Auto-routing to area owners and EHS based on zone

Audit Proof Captured

  • Audit Proof Icon Time-stamped submissions + ownership history
  • Audit Proof Icon Repeat-theme tagging for prevention planning
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Safety Alerts + Audits + Investigations

Configured for: Cross-plant learning and consistent closure discipline.

Key Workflow Controls

  • Check Icon Enterprise safety alert broadcasting workflows
  • Check Icon Recommendation distribution for similar-risk areas across plants
  • Check Icon Digital audits that auto-create actions from findings plants

Audit Proof Captured

  • Audit Proof Icon Alert-to-action traceability
  • Audit Proof Icon Audit compliance scoring visibility across plants

Workflow at a Glance

1

Trigger

Near-miss or behaviour observation is captured on mobile at the point of work.

2

Review

EHS validates severity and assigns ownership based on zone and category rules.

3

Execution

Owner closes the action with evidence; safety alerts are broadcast where the same risk exists.

4

Closure

Investigation and CAPA complete with verification before final closure.

5

Visibility

Dashboards track near-miss volume, investigation speed, audit score, and repeats across plants.

Field capture view UI

Near-miss + BBS capture view with routing and evidence

Corporate dashboard view UI

Enterprise safety alerts + cross-plant audit compliance view

Measured Outcomes

Measured Outcomes Icon

More reporting

72% increase in near-miss reporting volume

What Enabled It Mobile capture + simplified reporting
Measured Outcomes Icon

Lower incident rate

36% reduction in recordable incident rate

What Enabled It More signals + faster action closure
Measured Outcomes Icon

Faster investigations

49% faster incident investigation completion time

What Enabled It Structured investigations + linked actions
Measured Outcomes Icon

Fewer equipment repeats

28% reduction in repeat equipment-related safety incidents

What Enabled It Enterprise alerts + repeat-theme tracking
Measured Outcomes Features Icon Role-Based Access Control
Measured Outcomes Features Icon Immutable Audit Trail
Measured Outcomes Features Icon PDF/Excel Exports Available
Measured Outcomes Features Icon Offline Field Capture

Ready to build a near-miss culture that scales?

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