In the manufacturing world lies a series of hazards mostly from the constant moving of machine components. The safety of manufacturing workers is crucial in the center of the sector, and the overall performance of the workers typically depends on how efficiently the hazards are managed. Recognizing and reducing these hazards is not just a regulatory requirement; it’s a moral and social responsibility of manufacturing companies to ensure that each employee can work safely and return home without harm. This study was designed to investigate hazard recognition and control processes within a food and beverage manufacturing plant, evaluate current safety management practices, and develop evidence-based recommendations for improving workplace safety performance. The research employed a mixed-methods case study approach conducted over three months from September to November 2023. Data collection utilized existing company safety records, including incident logs, training materials, safety committee inspection reports, and audit documentation covering all operational areas and employee categories. Systematic analysis employed hazard identification tools, including Job Hazard Analysis, inspection checklists, and risk assessment matrices, to categorize and evaluate workplace hazards. The study identified twelve primary hazard categories across operational areas, with physical hazards representing 34% of total identified risks. Analysis revealed significant gaps in hazard recognition processes, inadequate machine guarding at critical operational points, and deficient design controls contributing to serious injury incidents. The tank lid injury case study demonstrated how unrecognized design hazards combined with procedural gaps create serious safety risks despite established cleaning protocols. The results showed that systematic hazard identification processes, when properly implemented with comprehensive employee engagement and regular monitoring, can substantially improve workplace safety outcomes and reduce incident rates in manufacturing environments.
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