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Johnson & Johnson Interdisciplinary Tour – October 30, 2025
On Thursday, October 30, 2025, a group of 25 UC ERC students, faculty, and staff participated in a tour and presentations from Johnson & Johnson in Cincinnati. The group was made up of participants from all the ERC academic programs (industrial hygiene, safety engineering, occupational health nursing, and occupational medicine), making it a truly interdisciplinary experience. The group learned about many different aspects of the safety and health operations at Johnson & Johnson including tours of RDL, Pilot Floor, Robotics, 3D print center, institute labs, and the clinic. The group then returned to a conference room for a Q&A session. This blog includes the experiences on the tour written by the students in attendance.
Photo caption: ERC group at Johnson & Johnson
Pilot Floor
Written by Khawla Ismail-Abderrezaq and Kymiah Blair
The pilot floor is a crucial stage between laboratory research and product development, where new medical devices and pharmaceutical products are examined, refined, and authorized. The professionals comprise quality inspectors, environmental health and safety officers, manufacturing process engineers, maintenance employees, management specialists, as well as mechanical and chemical engineers. These professionals work together to ensure that every product complies with the invention and conformity guidelines before mass production begins.
Operating on the pilot floor includes various possible risks. The workers could encounter high temperatures, high-pressure methods, chemical exposure, ergonomic hazards from repetitive duties, as well as mechanical risks from tools with moving parts. Testing of new products and procedures help identify hazards before transitioning to the manufacturing settings.
Johnson & Johnson utilizes a coated safety structure to handle these risks. This involves conducting hazard evaluations prior to establishing new processes, as well as implementing engineering controls (e.g., tools, safeguards, and ventilation systems) and administrative controls (e.g., work permits and standard operating procedures). The workers receive inclusive safety training as well as proper PPE that involves safety glasses, safety gloves, and a protective suit, which is obligatory; there are consistent environmental health and safety audits, as well as accident inspections, to assist in continual enhancement.
Johnson & Johnson's pilot floor ensures that the product development proceeds securely, safeguarding the employees and product quality, while supporting the company's global safety guidelines.
J&J MedTech, Ethicon
Written by Angela Theil and Judith Arthur
We were welcomed on our visit to Johnson & Johnson MedTech, located in Cincinnati, by a UC ERC graduate of the Occupational Health Nursing program, Tammy Lockhart. Tammy is the Site Team Lead of Global Health Services at Johnson and Johnson. We were warmly received by Tammy Lockhart, who, along with other EHS personnel, provided an in-depth tour and detailed breakdown of how the company successfully integrates good manufacturing practices, research and development (R&D), and pre-market device testing to advance client health and safety.
Photo caption: (from Left to Right) Tammy Lockhart (ERC OHN program alum), Dr. Beverly Hittle (OHN program deputy director), and Dr. Elizabeth McKinley (OHN program faculty and interdisciplinary trip lead)
J&J is a parent company that includes several specialized subsidiaries, holding over 7,000 patents. Their operations strictly follow regulatory policies from the FDA, USEPA, and ISO standards, with a focus on environmental sustainability and expert training.
We toured several divisions within the company, witnessing firsthand how the R&D division, in collaboration with the engineering department, designed and tested innovative, state-of-the-art biomedical equipment . The R&D team testing ensures adherence to good manufacturing practices by employing a multistep analysis process to understand the end-user experience and how surgeons and nurses interact with their products during surgeries. In addition, the facility has a 3D lab and Bioskills lab that allows for training and testing of their products for refinement. Beyond designing biomedical products, J&J also gave back to its community through community events, reflecting its commitment to science and civic responsibility.
Overall, we were impressed by J&J’s ethical standards, safety culture, and dedication to enhancing clients’ safety and health through innovative designs and high-quality biomedical equipment manufactured under strict regulatory guidelines.
J&J Innovative Medicine and J&J MedTech
Written by Amour Dondi
My visit to the Johnson & Johnson facility was informative and educational. We toured several departments and learned about advanced medical equipment and technologies. I was particularly impressed by the site’s security protocols, which are sophisticated and clearly designed to enhance worker safety. Overall, the site operates as a global healthcare hub staffed by skilled professionals focused on Innovative Medicine and MedTech.
From what I learned, the Innovative Medicine division concentrates on developing products for areas of high patient need, including oncology, immunology, neuroscience, and cardiopulmonary care. MedTech focuses on creating advanced devices intended to help people live longer and healthier lives, with particular emphasis on cardiovascular, orthopedics, surgery, and vision. Together, these divisions demonstrate J&J’s broad commitment to both therapeutic and device-based solutions.
J&J Medtech, Ethicon which is housed within the facility, was a standout. It serves as a major center for research, development, and engineering of surgical technologies such as sutures, staplers, and robotics integration. The work there highlighted the interplay between innovation and practical surgical needs, and the team’s expertise was evident throughout our tour.
Safety programs and controls were clearly prioritized across the site. I observed a hazardous communication program consistent with 29 CFR 1910.1200, including Safety Data Sheet (SDS) binders and emergency response equipment like eyewash stations, showers, and fire extinguishers. Personal protective equipment was used appropriately, especially where tissues are handled and advanced local exhaust ventilation systems were in place to capture contaminants at the source. Administrative controls included regular air monitoring, routine biomonitoring of employees, and an onsite medical facility that can provide vaccinations and other care.
Finally, I appreciated the hospitality extended by the J&J professionals and the thoughtful gifts we received. The visit offered a valuable glimpse into how a global medical device company integrates innovation, engineering, and safety to support workers and improve patient outcomes. Overall, it was a great day with meaningful takeaways.
Human Factors in Designing Surgical Instruments
Written by Mercy Omoifo-Irefo and Benjamin Goulart
Our recent field trip to Johnson & Johnson (J&J), a company founded in 1992 and now a leader in medical technology, offered an insightful look into the role of human factor engineering in designing surgical instruments. Originally focused on manufacturing, J&J now specializes in advanced instruments, robotic surgery, and training over 1,000 healthcare professionals annually. The tour highlighted a human factors approach, involving medical and safety personnel, industrial designers, and interface strategists.
J&J’s team uses cutting-edge research methods in simulation setting and field studies to optimize surgical tools. The research & development team uses a variety of tools to observe during procedures and capturing precise timestamps for each step. As the diversity of surgical staff has expanded to include both genders, anthropometric models ensure designs fit diverse hand sizes, from 50% of males and females to over 90% of the population. These insights guide iterative design processes: observing, designing, leveraging technology, evaluating risks, and refining tools to eliminate defects and enhance safety for practitioners and patients.
A key revelation was J&J’s use of single-use instruments, which simplifies sterilization, reduces wear, and meets cost-effective price points. Surgeons collaborate with J&J staff to address specific issues, such as handle shapes causing unnatural flexion, ensuring tools are intuitive and reliable. The design process transforms complex data into actionable solutions with safety components built in for maximum reliability.
The visit was a fascinating dive into how J&J integrates human factors, technology, and professional collaboration to create trusted, high-standard medical tools. The tour provided a glimpse into the future of surgical innovation.
Employee Health and Safety
Written by Kera Studer
Overall impression of Johnson & Johnson (J&J) was that the facility had a campus-like feel. There were many buildings on-site which provided other services for the company. J&J MedTech, Ethicon division is the building we toured and was once a manufacturing facility. One of the first things noticed was information posted regarding mental health care and onsite wellness services for their employees.
Potential exposures on site included radiation, chemicals, and noise. The site adheres to the hearing conservation, respiratory protection, and radiation guidelines set forth by OSHA. However, their standards go above and beyond state and federal guidelines. For example, OSHA requires workers to be enrolled in the hearing conservation program if their time weighted average (TWA) exceeds 85 decibels. J&J enrolls their workers at 80dBl’s or above. Another surveillance program that was a new learning, was their ergonomic surveillance. Workers are screened annually for ergonomic changes.
The safety culture at J&J was impressive. The are proactive with hazard recognition and encourage all employees to participate without fear of retaliation. They strongly encourage all employees to own their own safety, and to have the courage to speak up to their peers when witnessing intended, or unintended, violations. Workers are also encouraged to empower others, and to report all incidents. This strategy seems to work for this site, as their recordable rate is low compared to the number of workers employed.
Research Development Lab
Written by Ben Kraus, Lisa French and Onyinye Ezeifeka
The Johnson & Johnson Research Development Lab in Cincinnati brings together scientists, engineers, toxicologists, industrial hygienists, and product developers who work at the front edge of health-focused innovation. Their daily activities range from formulation testing to prototype evaluation, microbial assessments, analytical chemistry, and materials research. Although the lab classifies its hazards as minor, each task still requires strict attention to safety.
Common injuries in the lab include minor lacerations, so staff wear steel-toe shoes to prevent harm from dropped tools or equipment. Handling tissue introduces a biological exposure pathway that is managed through strict hygiene protocols. Some teams work with X-ray units, so dosimeters are worn to track cumulative radiation exposure.
Common hazards include low-level chemical exposure from solvents and reagents, potential skin or eye irritation from active ingredients, handling of compressed gases, thermal risks from heating equipment, and ergonomic strain from repetitive pipetting or extended bench work. Instrumentation may also carry electrical or mechanical risks during operation or maintenance.
To keep these hazards controlled, the lab relies on layered mitigation strategies. Engineering controls such as fume hoods, local exhaust ventilation, splash guards, temperature-controlled devices, and lockout protocols are standard. Administrative controls include well-defined SOPs, training modules for new and existing staff, equipment-specific certifications, and clear labeling systems that reduce uncertainty during experiments. Employees also complete routine safety refreshers and near-miss reporting to strengthen situational awareness. Appropriate PPE, such as lab coats, safety glasses, nitrile gloves, and face shields, adds another level of protection when equipment or procedures require it.
The lab’s emphasis on risk anticipation rather than reaction underlines its safety culture. Even when dealing with lower-hazard materials, the team approaches each project with the understanding that controlled environments, consistent training, and disciplined workflows protect both people and research quality.
Research Development Lab - professionals involved, hazards, mitigation of hazards
Written by Max Matura
The Cincinnati site of J&J MedTech, Ethicon is a hub of innovation where new surgical hardware, advanced instrumentation, and medical-device platforms are developed. At the facility, cutting-edge design meets various safety and regulatory requirements which shape up the products that are produced.
The professional team at the research and development lab consists of many multi-disciplinary fields. Firstly, the professionals involved often consist of various research and development engineers (mechanical, electrical, software, robotics) who spend their time designing and prototyping new surgical instruments, robotic devices, and digital interfaces. Another key facet of the professionals working at the research and development lab are the Data Scientists who directly process the numerical results from tests while also performing simulations to verify. As well as this, environmental health & safety professionals are also a key backbone in this team to ensure that standards and regulations are followed exactly.
Some of the different chemical hazards that are present on the site in the Research and Development labs are: adhesives, strong acids, cleaning agents, and solvent washes. To mitigate these hazards, the lab will use a written chemical hygiene plan, proper labeling of chemicals, functioning fume hoods, exhaust ventilation, and ensure proper personal protective equipment is utilized. Some of the different physical hazards that are present on the site are: various types of heavy machining equipment, punch presses, heavy robotic arms, test rigs, and other various moving parts. How these hazards are properly mitigated include: hazard identification, identification of failure modes, mitigating user errors, and proper training of all employees. Through rigorous procedures, strong safety culture, and well-trained personnel, the facility generally mitigates hazards and enables innovation in a safe and compliant way.
Industry Standards and Regulations
Written by Hannah Frame and Tigist Zewde
On October 30, 2025, the University of Cincinnati (UC) Education and Research Center (ERC) students visited Johnson & Johnson MedTech in Blue Ash, Ohio. Throughout the tour, it was emphasized that Johnson & Johnson is an international company with multiple functions. At the J&J MedTech, Ethicon location, there are a variety of chemical and physical hazards that workers could be exposed to. To ensure uniform standard application across all branches of Johnson & Johnson, the company follows ISO 14001, an international standard for environmental safety. However, Johnson & Johnson takes their compliance with standards a step further and details their own set of standards that are more protective of worker health and safety. These standards are detailed in their handbook and are audited at least once every three years. The company’s standards include components like beginning a hearing conservation program if a worker is exposed to 80 dBA (compared to the Occupational Safety and Health Administration’s standard of 85 dBA). If a standard requires weekly monitoring, the team at Johnson & Johnson will engage in daily monitoring to ensure that possible exposures can be recognized and mitigated early. There is also an ergonomic surveillance program implemented on workers who lift materials. These workers are assessed once annually for back, neck, and shoulder problems and carpal tunnel syndrome.
Johnson & Johnson also works closely with several external agencies including the Blue Ash Fire Department, The Environmental Protection Agency, The Hamilton County Health Department, the Food and Drug Administration, and the Metropolitan Sewer District to ensure adequate health and safety measures and effective collaboration. As an example, the team at Johnson & Jonson tests their drinking water and waste water once annually to ensure that they are being good environmental stewards and supplying good quality water to their workers. They collaborate closely with the Metropolitan Sewer District on these tests.
Another component of compliance with standards and regulations includes the occasional visits of inspectors from places like the Environmental Protection Agency and Occupational Safety and Health Administration. When these visits occur, a member from the Environmental Health and Safety team escorts the inspector and makes specific notes of any changes that need to be made. The team stressed that they want to work with the auditor firsthand so that they may pragmatically and specifically address any issues as they are realized. This also makes sure that the team has appropriate follow-up on any existing hazards, ensuring that non-compliant components are addressed in a timely manner.
Safety Culture at Johnson & Johnson
Written by Chien-Yu Hsu
During our visit to Johnson & Johnson, I was deeply impressed by the company’s strong occupational safety culture. As a global company, Johnson & Johnson not only follows legal safety standards but also goes beyond them. For example, their noise surveillance limit is set at 80dBA which is even stricter than the regulation.
The company believes that safety is everyone’s responsibility. Every employee is encouraged to “own” their safety and also look out for their coworkers. This culture empowers everyone to speak up, follow safety rules, and make sure that all workers wear the proper personal protective equipment, such as safety shoes and glasses. Their goal is for everyone to go home in the same healthy condition as when they arrived.
Johnson & Johnson also cares about mental health. They provide free counseling services, and employees can join different wellness and ergonomic activities to maintain a healthy mind and body.
Common workplace risks, like cuts and slips, are managed through continuous safety training and supervision. The company also focuses on protecting the environment by monitoring groundwater, wastewater, and soil to ensure there is no harmful emission.
Through these efforts, Johnson & Johnson shows that true safety culture is not just about rules and regulations—it’s about caring for people, both physically and mentally, and protecting the environment that supports us all.
Written by Slater Payne
Ethicon, a subsidiary of Johnson & Johnson, is a medical device company that produces a range of specialized surgical products. They also offer specialized surgical training for employees and clients. The surgical suite used for these training courses was part of the larger tour that several of my colleagues and I were given of the larger Ethicon facility. Overall, it was a very informative tour, and I am deeply grateful for the opportunity to tour such a well-run facility. These are just some of the occupational safety highlights that stuck out to me during our tour of the Institute Labs.
Preventive measures such as vaccine requirements, specialized equipment, and PPE help to limit potential exposure to biological agents. Unique instruments such as surgical tools that use thermal destruction are connected to smoke evacuator systems which can’t be disconnected from the tool. This helps to control release of surgical plumes during training and the fact it can’t be detached prevents modification by users which could hinder the ventilation systems effectiveness.
More administrative controls used at the site include air monitoring conducted by the safety team on a regular basis, which helps to determine the effectiveness of safety tools like the smoke evacuator system. The facility also has onsite medical facilities with the ability to provide vaccinations on site to help protect workers against potential hazardous diseases they may encounter from samples. As part of this effort, the safety team also utilizes a regular biomonitoring program for all employees.
While a few questions remain regarding the potential strain from lead vests, this topic feels better suited for a future research project given the wide use of lead vests in healthcare. The facility provides vests in different sizes with multiple attachment points to help distribute the weight of the lead vest.
Written by Grace Adkins, Kofi Osei-Acheampong, Ana Littrell
On a rainy Thursday morning we were afforded the opportunity to visit the Ethicon facility, which is part of the J&J family. The Ethicon campus appears to be a well-planned, multi-building facility that supports its role in medical device manufacturing, innovation, and corporate operations under Johnson & Johnson MedTech. The campus design reflects a blend of functionality, safety, wellness, and environmental consideration.
Key building identified are:
The facility employs approximately 1400 workers. Of these, there are 1100 associates and 300 contractors.
During the tour it was explained that the site used to be a manufacturing facility but had transformed into research and development. Products are no longer manufactured on site at a large scale. Instead, the company leverages their collaboration with biology, engineering, clinical, and manufacturing teams for their product designs and development. Ethicon’s Cincinnati campus is known for being a global hub for medical device design, research, and development. The facility supports Product design and engineering of surgical solutions, such as:
It was a great experience that ended with a small debriefing and Q&A session. Thank you!
Thank you to our guides at Johnson & Johnson for taking the time to tour the facilities with our ERC group, answer questions, and teach us about your health and safety practices and current research.