Daniel Doerrfeld Manufacturing operations leader @

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FloorSignal: a near miss reported in thirty seconds, fixed in the open

Safety, Culture, ’26 — Concept and interface design

Concept Specified and mocked up, not yet deployed. Every plant, person, and figure in the screens is fictional.

Triage board with report cards in four columns, Submitted, Owned, Fixed, and Verified, each card showing type, severity, location, owner, and due date, and a banner for reports with no owner
Role
Concept and interface design
Year
2026
Tools
Concept deckInterface mock-ups

Overview

A QR code on every machine opens a phone form; reports land on a triage board with an owner and a due date, and the floor sees what was fixed.

Problem

Most near misses are never written down, because writing one down takes longer than the near miss did.

The form lives in an office or on a clipboard, it asks who was involved, and nothing visible happens afterwards. So the hazard that almost hurt someone on second shift is still there on third, and the only record of it is a conversation. Safety programs then measure what did happen, because nothing was captured about what almost did.

Approach

Make the report faster than the walk to the supervisor, give every report a named owner and a due date, and show the floor what was fixed.

A QR tag on every machine, aisle, and dock door opens a phone page with that location already filled in. No app, no login, name optional. The worker picks near miss, hazard, unsafe condition, or good catch, speaks or types one sentence, adds a photo, and sends. The form asks one question first: was anyone hurt? A yes routes to the incident process and the extension to call, because an injury needs care and an investigation, not this tool.

The report lands on a triage board for the area supervisor and the safety lead in four columns. Submitted must become Owned within four working hours; severity sets the due date to fix; overdue turns red; and Verified is confirmed by someone other than the fixer. A report with no owner sits in a banner at the top of the board until it has one. There is no field for who caused it. Trends are by area, shift, and hour, so the heat map shows the dock door at shift change rather than a person.

The loop closes in public. A floor display and a weekly digest list what was reported and what was done, with fixes named and reporters never named. A reporter who left a number gets a text at each state change. Leaders file reports too, and the board shows it.

Outcome

Measured outcomes
Metric Result
Status Concept, in development
To report Under 30 seconds, no app, no login
Ownership A named owner within four working hours
States Submitted, Owned, Fixed, Verified

Built to move five numbers, each computed from the tool’s own records.

Reports per hundred employees per month should rise, because underreporting is the problem being solved. Median days to close and the share closed within thirty days are the speed of the loop. Repeat hazards per area should fall as the heat map does its work. The ratio of near misses reported to recordable incidents is the honest leading indicator, and the recordable rate and severity are the lagging ones, read quarterly.

Nothing here has run on a floor yet. The screens are a specification with fictional data, and the numbers on them are placeholders.