This article discusses the relationship between workplace safety and production management systems while analysing the empirical application of the lean thinking approach. In particular, this paper aims to determine whether the application of lean practices has beneficial effects not only on production efficiency but also on the health and safety of workers. The analysis is divided into two main stages: first, a review of the relevant literature was developed, followed by a case study analysis in an Italian metal casting company describing two continuous improvement projects from a workplace safety point of view. Both continuous improvement projects pursued the reduction of production interruptions and the elimination of defects, respectively. Research findings indicate health and safety conditions improvements after the implementation and application of various lean practices, especially by reducing risk exposure in the first project and improving the level of ergonomics in the second. This paper is of great interest for both researchers and practitioners since it suggests various possible relationships between the continuous improvement approach, provided by a practical application of the lean philosophy, and the improvement of workplace safety while fostering production efficiency.