Episode 164 - Do the Research Upfront to Understand the Hazards of Equipment

Episode 164 drives home a simple but powerful message: you cannot lead safety around equipment you don’t fully understand. Dr. Ayers explains that many incidents happen because leaders skip the research phase and jump straight to solutions, relying on assumptions instead of facts. Effective safety leadership begins with learning the equipment, the hazards, and the work as performed.

  🔑 Key Takeaways 1. Leaders Often Assume They Know the Equipment

Common shortcuts include:

• Relying on outdated knowledge

• Assuming similar equipment works the same way

• Trusting vendor brochures instead of digging deeper

• Writing procedures without seeing the equipment in use

These shortcuts create blind spots.

  2. Every Piece of Equipment Has Unique Hazards

Dr. Ayers stresses that leaders must understand:

• Mechanical hazards (pinch points, rotating parts)

• Stored energy (hydraulic, pneumatic, electrical)

• Chemical hazards (lubricants, coolants, fumes)

• Operational hazards (speed, load, movement patterns)

• Maintenance hazards (lockout points, access issues)

You can’t control hazards you haven’t identified.

  3. Research Must Happen Before Decisions Are Made

Effective leaders:

• Read the manual

• Review manufacturer hazard information

• Observe the equipment in operation

• Talk to operators and maintainers

• Verify assumptions with real data

This prevents costly mistakes and rework.

  4. Workers Know the Equipment Better Than Anyone

Skipping research leads to:

• Procedures that don’t match reality

• Controls that don’t work

• Workers losing trust

• Leaders appearing disconnected

Research shows respect for the people doing the job.

  5. Up‑Front Research Reduces Risk and Drift

When leaders understand equipment hazards:

• Controls are more effective

• Training is more accurate

• Near misses are easier to interpret

• Weak signals are easier to spot

• Safety culture strengthens

Preparation is a form of prevention.

  🧩 Big Message

Episode 164 reinforces that safety leadership starts long before a hazard assessment or procedure is written. Leaders must do the research up front — understand the equipment, the hazards, and the work — so decisions are grounded in reality, not assumptions. When leaders skip this step, the organization pays for it later.