Many industrial plants and warehouses still struggle with proper signage. While this may seem straightforward, errors in production hall signage can significantly reduce work efficiency, increase the risk of accidents, and generate unnecessary costs.

In this article, we show what mistakes occur most often and how a conscious approach to Visual Management and health and safety signage can completely change the way a plant operates.

 

Why is proper labeling of production halls crucial?

Well-planned signage in production halls is more than just aesthetics. It's the foundation of safety, organization, and visual communication. According to the European Agency for Safety and Health at Work (EU-OSHA), over 20% of industrial accidents are caused by organizational errors and a lack of clear signage.

Appropriate occupational health and safety signage supports not only safety but also the smooth running of processes – it shortens employee travel times, reduces logistical errors and streamlines the introduction of new people to the team.

Well-designed signs:

⚠️ reduce the number of accidents,

⚠️ improve the flow of materials and people,

⚠️ support Lean and 5S implementations,

⚠️ reduce costs associated with errors and downtime.

 

The most common errors in the marking of production halls:

 

❌ Lack of consistency and standardization

One of the biggest problems is the lack of uniform rules. Lines painted in different colors and styles, illegible pictograms, or makeshift markings made with duct tape create chaos instead of order. This not only reduces the effectiveness of visual management but also confuses employees.

❌ Poor placement of health and safety signs

Standards clearly define the height and placement of signs. However, in many warehouses, signs are obscured by shelves, machinery, or are too high to be legible. Health and safety signage that is not visible is ineffective.

❌ Savings on materials

A common mistake is choosing the cheapest tapes and boards, which wear out after a few weeks. As a result, the company has to reinvest in signage, which increases costs and disrupts workflow. However, carefully selected materials – such as heavy-duty tapes – can withstand even intensive use.

❌ No sign updates

Processes in industrial plants are constantly changing. New machines, shifted production lines, and additional racks all require updated signage. Too often, companies overlook this necessity, and employees use outdated systems, generating errors and risks.

 

How to avoid errors in health and safety labeling?

A holistic approach is key – from a space audit and analysis, through a design tailored to real needs, to personalized production and installation. Only such an approach ensures that occupational health and safety signage works in practice, not just "looks good."

Examples of effective solutions include durable magnetic frames, visual boards, and abrasion-resistant painted lines. These ensure the system remains legible and easy to maintain for years to come.

 

Visual Management as an answer to problems

Visual Management is an approach that treats signage as a process management tool. Implemented correctly, it allows for:

• clear separation of production, logistics and social zones,

• clear marking of transport and evacuation routes,

• support for the implementation of Lean and 5S standards,

• minimizing the risk of accidents.

According to a report by the Fraunhofer Institute (2023), the implementation of visual management systems in production halls can reduce the number of errors by 30–40% and shorten the time of operations by up to 20%.

 

Summary

Signage in production halls is an area where there's no room for compromise. Mistakes—such as inconsistency, illegible signs, or skimp-on materials—can cost a company significantly more than investing in professional solutions.

That is why it is worth investing in a well-thought-out Visual Management that not only improves safety, but also supports Lean, Kaizen and 5S, increasing the efficiency of the entire plant.

We've prepared a Sample Box – a set of product samples you can test in your facility. This will allow you to see which solutions are best suited to your company's needs before deciding on a larger-scale implementation.