5 Common Risks In Manufacturing Companies

The manufacturing industry is booming. Despite the difficulties of the post-pandemic period and ongoing geopolitical tensions, global production is growing steadily. According to a new UNIDO report, the production and export of goods increased by 1.3 and 1.4 per cent respectively at the beginning of 2025. Factories are running at full capacity, particularly in China, Europe and North America.

However, with this growth comes increased exposure to risks, such as more movement at gates and loading docks, and more complex shift schedules, which increase the potential danger. At the same time, stricter safety and privacy regulations are in force. In this article, we discuss five common risks in manufacturing companies and offer practical measures to mitigate them. Alongside safety procedures, training and maintenance, digital visitor management (VMS) plays a vital role in your safety processes.

We will cover the following risks:

• Occupational risks
• Emergencies
• Cyber risks
• Intruders
• Compliance risks

Read on for practical information about the use and benefits of a visitor management system in the manufacturing industry.

1. Occupational risks

No matter what industry you’re in, automotive, mechanical engineering, chemicals, metals, or pharmaceuticals, workplace safety is the most important concern for every production facility. There are many potential hazards on the production floor, including heavy machinery, internal transport with forklifts and pallet trucks, working at heights, hot surfaces and steam, chemicals, electrical installations, and pressurized pipes.

There may also be exposure to hazardous substances, fumes, or noise. Physical strain from heavy work or repetitive movements also poses risks.

Temporary workers, contractors, and visitors are especially vulnerable in this context. They are less familiar with the site, procedures and rules, may not always recognize signs or color codes, and do not always speak the same language. A seemingly minor mistake, such as taking the wrong route or entering a hazardous area without protective equipment, can quickly lead to an incident.

Practical measures for occupational risks in manufacturing companies

• An important first step is physical security. This includes providing sturdy guards and interlocks on machines, properly functioning emergency stops, clear zone demarcations, and separate pedestrian routes.
• Ensure that risk zones are only accessible to authorized personnel, and that each person has access only to the zones necessary for their work. This can be achieved with a combination of access control, digital visitor management, and personal badges.
• Provide clear signage with multilingual signs and pictograms.
• Specify mandatory protective equipment for each zone, and ensure it is available and being worn.
• Focus on prevention and training by carrying out periodic risk analyses and holding regular (multilingual) training and practice sessions.
• Give visitors, temporary employees, and contractors a brief multilingual safety briefing in advance, and issue temporary visitor badges with zone and time restrictions via the digital visitor management system.

Want to learn more about how digital visitor management can improve security at your production facility? Read the article.

2. Emergencies

Of course, you want to avoid emergencies. In a production environment, however, events can unfold quickly. Examples include a fire caused by a machine or electrical fault, a gas leak or chemical spill, smoke development, a small explosion, power failure, flooding, or a medical incident on the work floor.

If an evacuation is necessary, many things must happen simultaneously within a few minutes. Mobile equipment must be stopped, production lines must be shut down, and hazardous areas must be cleared for emergency services. Meanwhile, the outdoor area must not be forgotten, including traffic at the loading docks, shuttling forklifts, and open storage of materials or hazardous substances. In such a busy environment, it is essential to quickly and reliably determine who is still inside and where they are located, including visitors, drivers, and contractors.

Practical measures for emergencies in manufacturing companies

• Develop clear and specific emergency scenarios for situations such as fires, gas or chemical leaks, power failures, and medical incidents. Practice these scenarios regularly.
• Ensure reliable detection and alerting. Alarm sirens and flashing lights must be audible and visible everywhere, even where hearing protection is worn.
• Keep evacuation routes and emergency exits clear. Designate clear assembly points and ensure that night and weekend shifts also know where to go.
• Communicate clearly and in multiple languages. Use fixed announcement templates, visual instructions, and additional channels, such as walkie-talkies, public address systems, and text messages or push notifications. Provide an emergency plan in case the network or power fails.
• Work with a visitor management system (VMS) that maintains an up-to-date attendance list for each site or zone. In the event of an evacuation, you can quickly verify who is safe and who may still be inside. The VMS can also send emergency notifications to people in the building or on the premises.

Good crisis planning is essential for any manufacturing company. Read more about it in our guide to emergency preparedness.

3. Cyber risks

Cyber incidents pose an ever-increasing threat to businesses. Ransomware can target production facilities at the heart of their operations. As production technology becomes more connected to IT systems, the attack surface expands. A single weak spot can shut down entire production lines or render control and planning systems unusable.

The human element should not be overlooked: phishing and reused passwords remain common entry points. Visitors, drivers, and temporary workers introduce additional risks. External technicians sometimes have temporary access to systems, and visitors use their own laptops and phones. Not everyone is familiar with your rules regarding photography, Wi-Fi, or connecting equipment.

Data is also a target. Consider product recipes, CAD drawings, supplier and customer data, and personnel data. Theft or leaks can lead to financial loss, a competitive disadvantage, reputational damage, reporting obligations, and fines under the General Data Protection Regulation (GDPR).

Practical measures for cyber risks in manufacturing companies

• Empower employees with training and campaigns to ensure they recognize phishing attempts and use strong passwords or a password vault.
• Protect sensitive data through encryption, data minimization, and clear retention periods. Log who accessed what information and when in line with the GDPR.
• Provide visitors with clear guidelines. Offer separate guest Wi-Fi and prohibit connection to internal networks. Make photo and device policies visible and multilingual.
• Use the visitor management system to have visitors confirm non-disclosure agreements (NDAs) and house rules in advance, to issue temporary IT access in a controlled manner, to record who was where during work or audits, and to protect visitor data.
• Limit the attack surface by separating networks (office and production), disabling unused ports and Wi-Fi access, and systematically implementing updates and security patches.

Why are more and more companies being hit by cyberattacks? How can you prevent your company from becoming the next victim? You can read all about it in this article.

4. Intruders

Intruders pose a real risk in production environments. Large sites with multiple gates, entrances, loading docks, and outbuildings can be difficult to oversee. An intruder who slips in unnoticed may be after valuable goods, raw materials, or information such as photos of processes, layouts, or recipes.

Practical measures for intruders in manufacturing companies

• Use a visitor management system (VMS) for pre-registration and identity verification to ensure that only pre-registered and verified visitors enter the facility.
• Issue temporary, personalized badges with zone and time restrictions.
• Link the system to access control and license plate recognition systems so that barriers, doors, and turnstiles only open for authorized visitors and drivers.
• In addition, ensure good lighting and camera surveillance at access gates, entrances, and loading docks.
• Establish escort rules for critical zones and automatically notify hosts when their visitors arrive who require escorting.

How can you keep your business and staff safe? Read more about it in our article on a safe workplace.

5. Compliance risks

Laws and regulations are constantly changing. Safety, quality, and privacy requirements are becoming stricter and can vary by sector. Examples include ISO 45001 (occupational health and safety), ISO 27001 (information security), sector standards such as GMP (Good Manufacturing Practice), BRC (British Retail Consortium), and IFS (International Food Standard), and the GDPR (General Data Protection Regulation) for personal data.

During audits, you must demonstrate who was present, when they were present, and which documents or instructions they signed. Paper forms, emails, and separate spreadsheets make managing this information, monitoring retention periods, and controlling access to data difficult. Errors or omissions can lead to extra work, fines, and reputational damage.

Practical measures for compliance risks in manufacturing companies

• Work in compliance with the GDPR: only collect necessary data, grant access only to those who need it, and record who views or modifies data. Set retention periods with automatic deletion afterward.
• Provide a single, central location for all work instructions and forms. Use clear templates, and regularly verify that the correct version is being used in the workplace.
• Schedule regular internal checks. Record any discrepancies, identify the root cause, establish specific improvement actions, and perform another check.
• Determine the knowledge and skills required for each position. Provide targeted training and repeat it at regular intervals.
• Establish clear requirements regarding quality, safety, and privacy, and include them in contracts with suppliers and partners.

How does a visitor management system work in the manufacturing industry?

Production companies receive all kinds of visitors every day, including maintenance teams, contractors, loading dock drivers, auditors, and temporary employees. These visitors often enter through multiple gates in shifts and sometimes enter areas where strict safety measures apply.

Traditional paper-based visitor registration cannot control such a flow of visitors. Queues grow, errors creep in, and it is easy to lose track of who is inside. This makes it difficult to determine who is present, including in the event of an evacuation, and to comply with the GDPR.

That is why a structured, centrally controlled approach is needed. A digital visitor management system (VMS) can regulate the entire visitor process in a production facility.

Below is a brief overview of how a visit works:

1. The host registers the visit in advance, or the visitor fills out a short form.
2. The visitor receives a confirmation email with a QR code and practical information.
3. The visitor arrives at the gate or reception desk, checks in, and receives a badge or label. Additional steps may apply, depending on the type of visit. For example, drivers may need to provide dock information, and contractors may need to provide required documents.
4. The host automatically receives a notification that the visitor has arrived.
5. Upon departure, the visitor checks out, completing their visit.
6. All data and documents related to the visit are neatly and securely stored in the cloud.

Benefits of a visitor management system in manufacturing plants

In a safety-critical production environment where heavy machinery is present, sensitive materials are stored, and strict safety protocols are in place, a digital visitor management system offers many advantages. The most important ones are:

1. Better security

A VMS regulates visitor flow and keeps out unwanted visitors. Only verified visitors can enter within the agreed-upon time slot and zone. Safety instructions can be provided in advance or at check-in so visitors are aware of the basic rules before entering the premises. Furthermore, a VMS provides a constant overview of who is in the building. In an emergency, you have an up-to-date attendance list and can automatically send emergency notifications.

2. Greater efficiency

A digital visitor management system streamlines the registration process. Visitors can register in advance and quickly check in via a kiosk upon arrival. Badges print automatically, and NDAs or safety instructions can be integrated into the process. Hosts receive a real-time notification when their visitor arrives. This eliminates duplicate work at the gate or reception desk, allowing receptionists and doormen to focus on their core tasks.

3. Better visitor experience

For visitors, nothing beats a smooth and pleasant welcome. A VMS ensures just that. Your guests receive all the necessary information in advance and can quickly check in on site in their own language. Meanwhile, their host automatically receives a notification. Suppliers and drivers experience less waiting time and greater clarity about when and where they are expected. Customers and other visitors enjoy a professional, efficient reception without long lines or unnecessary questions. The result is a positive first impression that aligns with a safe, organized production environment.

4. Regulatory compliance

Manufacturing companies must demonstrate who entered the premises, when they entered, and which instructions or documents they processed. A VMS can simplify this administrative process. Visitor data is securely stored in the cloud. This allows you to generate audit-ready reports in just a few minutes. In accordance with the GDPR, the data is automatically deleted once the retention period has expired.

5. Lower costs

A digital visitor management system eliminates manual tasks from the visitor process. This allows receptionists and doormen to spend less time on repetitive tasks and be deployed more efficiently. Traffic flow at the reception area, gate, and loading dock improves, reducing the need for peak staffing. Since forms, NDAs, and instructions are handled digitally, paper and archiving costs are also lower. Finally, consistent registration and audit-ready data reduce the risk of fines.

Conclusion

In production environments, danger lurks around every corner. Some of the most significant risks include workplace safety, emergencies, cyber threats, intruders, and regulatory compliance. A visitor management system can help you mitigate these risks.

Pre-registration and check-in streamline reception; access rights per zone and time period keep unauthorized persons out; multilingual safety instructions reduce the risk of incidents; an up-to-date attendance list supports evacuations; and a complete audit trail demonstrates your adherence to the rules.

To see how digital visitor management can benefit your production facility, try Vizito for free for 14 days. Chat with us or book a demo to learn more.