How General Managers Can Implement Custom Safety Plans in Film and TV Production

In the high-stakes world of film and TV production, where cranes swing overhead and pyrotechnics light up the night, a general manager's role in safety can't be overstated. Custom safety plans aren't cookie-cutter documents—they're tailored blueprints that address the unique hazards of your shoot, from stunt rigging to underwater filming. I've seen productions grind to a halt over ignored risks; let's change that.

Step 1: Conduct a Thorough Hazard Assessment

Start with a site-specific Job Hazard Analysis (JHA), mandated under OSHA 1910.132 for general industry but amplified for entertainment under Cal/OSHA Title 8, Section 344.70. Walk the set with your department heads—grips, electrics, stunts—and document everything: fall risks from catwalks, chemical exposures in practical effects, or ergonomic strains from long camera hours.

• Map hazards by location: studio vs. location shoots.
• Quantify risks using a matrix—likelihood times severity.
• Involve union reps early; IATSE Local 728 and Teamsters emphasize collaborative input for buy-in.

This isn't busywork. On a recent indie feature I consulted for, pinpointing unstable scaffolding prevented a potential collapse during a night exterior.

Step 2: Draft Tailored Safety Plans and Procedures

Custom plans beat templates every time. Reference SAG-AFTRA's safety bulletins and the Alliance of Motion Picture and Television Producers (AMPTP) guidelines, but adapt them. For example, your LOTO (Lockout/Tagout) procedure for practical effects must specify exact energy sources—high-voltage generators or compressed air lines—not generic steps.

Structure your program like this:

1. Emergency Action Plan: Evacuation routes, mustering points, and AED locations, compliant with OSHA 1910.38.
2. PPE Protocols: Harness inspections for aerial work, per ANSI Z359.14.
3. Stunt and Special Effects Matrices: Pre-approval checklists with qualified coordinators.

We once customized a plan for a drone-heavy production, integrating FAA Part 107 rules with ground crew spotters. It kept shots flowing without FAA violations.

Step 3: Roll Out Implementation with Training and Drills

Plans gather dust without execution. Mandate safety meetings at call time—tailgate style, 10 minutes max—and full orientations for new hires. Use digital tools for JHA tracking if your budget allows, ensuring real-time updates.

Drill it: Weekly fire watch simulations for pyros, or harness rescue practice. I've watched GMs transform apathetic crews into safety pros by gamifying drills—who spots the hazard first gets coffee duty off.

Step 4: Monitor, Audit, and Iterate

Assign a dedicated safety officer reporting directly to you, the GM. Conduct daily walkthroughs and weekly audits against your plan. Log incidents via OSHA 300 forms, analyzing root causes with tools like the "5 Whys."

Post-production review is key. After wrap, survey the team: What worked? What nearly didn't? Adjust for the next gig. Research from the CDC's National Institute for Occupational Safety and Health (NIOSH) shows iterative programs cut entertainment injuries by up to 40%—real numbers from real sets.

Limitations exist: Budget crunches can tempt shortcuts, but fines from Cal/OSHA average $15,000 per violation. Balance is transparency—track metrics, share wins and misses openly.

Resources for Deeper Dives

• Cal/OSHA Entertainment Manual: dir.ca.gov/dosh/EntertainmentUnit.html
• OSHA Entertainment Industry Resources: osha.gov/entertainment
• IATSE Safety Resources: iatse.net/safety

Implementing custom safety plans positions you not just as compliant, but as the GM who delivers safe blockbusters. Your crew deserves it—and so does your bottom line.