Episode 208 - Bruce Main - Prevention Through Design (PTD)

In this episode, Dr. Ayers interviews Bruce Main, a leading expert in machine safety and risk assessment, to explore how Prevention Through Design (PtD) can dramatically reduce workplace hazards. Bruce emphasizes that the most effective safety solutions are those built into the design of equipment, processes, and systems — not added after the fact.

  🧠 Key Themes 1. The Best Time to Control Hazards Is Before They Exist

Bruce explains that PtD focuses on eliminating hazards during the design phase, when changes are:

• Cheaper

• More effective

• More reliable

• Less disruptive

Once equipment is built and installed, options shrink and costs rise.

  2. Engineering Controls Beat Administrative Controls Every Time

Bruce reinforces the hierarchy of controls:

• Eliminate the hazard

• Substitute safer options

• Engineer out exposure

• Administratively manage what’s left

• PPE as the last line

PtD is about living at the top of that hierarchy.

  3. Design Must Reflect Real‑World Use

A recurring theme: If a design doesn’t match how people actually work, it will fail.

Bruce stresses the importance of:

• Observing real tasks

• Understanding operator behavior

• Designing safeguards that support productivity

• Avoiding “idealized” assumptions

When design ignores reality, workers bypass controls.

  4. Collaboration Is Essential for PtD Success

Effective PtD requires input from:

• Engineering

• Maintenance

• Operators

• Safety professionals

• Leadership

No single group sees the full picture. Bruce highlights that PtD is a team sport.

  5. PtD Saves Money, Time, and Lives

Bruce makes the case that PtD isn’t just safer — it’s smarter business. Benefits include:

• Lower lifecycle costs

• Fewer retrofits

• Reduced downtime

• Better productivity

• Stronger safety culture

Designing safety in is always cheaper than bolting it on.

  🚀 Leadership Takeaways

• Eliminate hazards early — design is the most powerful safety tool.

• Engineering controls are the backbone of lasting safety.

• Design must reflect real‑world work, not idealized procedures.

• PtD requires cross‑functional collaboration.

• Investing in PtD pays off in safety, reliability, and cost savings.