Machine safeguarding

The ROI of Machine Safeguarding

Investing in machine safeguarding isn’t just about compliance—it’s smart business. While many companies look at safety as a cost center, the reality is that a properly safeguarded machine pays for itself many times over.

Why Safeguarding Pays Off

When a machine is properly safeguarded, you’re not just protecting people—you’re also protecting your bottom line. Injuries and accidents come with a high price tag, both seen and unseen.

Tangible Costs of a Workplace Injury
Direct & Measurable

  • Medical expenses
  • Workers’ compensation claims
  • Fines from OSHA or other regulatory bodies
  • Increased insurance premiums
  • Unplanned downtime and production delays
  • Damage to equipment and materials
  • Unexpected outsource work

Intangible Costs
Harder to Measure, Still Costly

  • Lower employee morale and retention
  • Reputation damage
  • Legal expenses and litigation risk
  • Loss of future contracts or customers
  • Disruption of operations and productivity
  • Employee Injury

A Simple Formula to Estimate ROI

We recommend using this straightforward formula—one that’s been backed by safety professionals and insurers:

ROI (%) = Estimated Savings from Accidents Prevented (– Cost of Safeguarding)/Cost of Safeguarding × 100

If no similar accident happens over two years, your ROI doubles.

Example:

$100,000 Per Year (Saved Medical/Downtime Fines) – $45,000 (Cost of Safeguarding) = $55,000

$55,000/$45,000 x 100 = 122% ROI

Real-World Impact

One business shared this story with us:

An employee injury cost them $67,000 in direct costs. But after downtime, missed deadlines, legal fees, and a lost contract, the total cost ballooned to over $670,000.

That’s the kind of financial hit that no spreadsheet or budget forecast sees coming—until it’s too late.

“ Workers who operate and maintain machinery suffer approximately 18,000 amputations, lacerations, crushing injuries, abrasions, and more than 800 deaths per year.”*
* https://www.osha.gov/SLTC/machineguarding/index.html

Safeguarding is a Smart Investment

While every facility is different, the math is clear: Spending now to prevent injuries saves far more than reacting later. Whether it’s through reducing downtime, avoiding fines, or boosting employee morale, the return on investment in machine safeguarding is real—and significant.

Want to estimate your ROI? Use our ROI Calculator to see the numbers for yourself.

Machine Safeguarding ROI Frequently Asked Questions

The cost of non-compliance; OSHA fines, litigation, downtime, and lost productivity, almost always exceeds the cost of a proper safeguarding program. These FAQs help safety and operations leaders make the business case. Want a number specific to your facility? Contact our team and we can help you build it.

What are the most common machine guarding violations and how can I avoid them?

Frequent citations include missing or misadjusted guards, bypassed interlocks, inadequate training, and insufficient safety distance. Beyond the human cost, OSHA citations, production downtime, and liability exposure add up quickly — a Safeguarding Policy Development program builds the preventive infrastructure that protects both people and your bottom line.
→ Talk to An Expert About Building Your Program

What steps should I take to retrofit aging machinery for modern safeguarding?

Start with a Remote Safeguarding Assessment to establish your baseline risk and cost exposure, then implement a prioritized plan of engineered guards, devices, and controls — maximizing protection per dollar invested.
→ Start With a Safeguarding Assessment

How often should machine guards and safety devices be inspected and tested?

At minimum: visual checks before each shift, after setup or maintenance, quarterly device testing, and an annual professional review. Consistent inspection cadence is one of the lowest-cost ways to maintain compliance and avoid costly unplanned downtime.
→ Schedule Your Annual Safeguarding Validation Audit

What training should operators and maintenance staff get for machine safeguarding?

Role-based training on hazard recognition, correct use and adjustment of guards and devices, and emergency stop and LOTO procedures. Documented training is also a critical element of demonstrating good-faith compliance — reducing penalty severity if an incident occurs.
→ Ask Us About Operator and Maintenance Training

When is a machine guard exemption allowed and what criteria apply?

Exemptions are rare and require a documented risk assessment showing no employee exposure. Attempting to operate without proper guarding — without that documentation — significantly increases liability and OSHA penalty exposure.
→ Contact Us to Discuss Your Compliance Position