Common Safety Risks in Manufacturing

Manufacturing floors depend on moving parts, stored energy and heavy equipment, all of which require safeguards to prevent employee injury. Identifying and mitigating these risks can also help manufacturing organizations comply with regulations and maintain productivity. Here are five common hazards and steps employers can take to address them.

1.      Electrical hazards

Exposed wiring, overloaded circuits and improper grounding can cause shocks, burns and fires. U.S. Bureau of Labor Statistics (BLS) data compiled by the Electrical Safety Foundation International show 120 electrical fatalities in manufacturing from 2011 through 2024, and 5,180 nonfatal injuries across industries in 2023-24. To reduce these and related risks, it’s crucial to ground equipment, use ground-fault circuit interrupters, inspect tools before each use, test electrical supply systems frequently and provide personal protective equipment (PPE) to workers.

2.     Lockout/Tagout Failures

According to preliminary 2026 data, OSHA’s control of hazardous energy standard had 1,863 violations. Servicing a machine that isn’t fully deenergized can cause electrocution, crushing injuries or amputations. Procedures for each type of energy should be followed to prevent injury or damage to machinery. Workers should be trained never to restart locked-out or tagged-out machines and retrained when procedures or equipment change. Audit lockout/tagout logs regularly and encourage workers to report deviations.

3.     Machine Guarding Incidents

Unguarded machines and poorly installed guards can increase entanglement, crushing and amputation risks. Preliminary 2026 OSHA data show machine guarding was cited 1,072 times. Employers should use guards that meet or exceed manufacturer specifications, and inspect them regularly. Workers can grow complacent and over-trust guards, so post warning signs near pinch points and balance workloads to reduce rushing.

4.     Slips, Trips and Falls

Wet or oily floors, cluttered walkways and uneven surfaces can cause sprains, strains and fractures. In addition, damaged or uninspected ladders add fall risk. Among all industries, the BLS reported 844 fatal slips, trips and falls in 2024. Clean up spills right away, mark uneven flooring, require nonslip footwear, install guardrails in elevated areas and ensure proper lighting.

5.     Powered Industrial Truck Incidents

Falling loads, struck-by-truck incidents, and falls from elevated pallets and tines are other significant hazards in manufacturing organizations. OSHA’s powered industrial trucks standard was cited 1,826 times in 2025. Employers must ensure each operator is competent, as demonstrated by training and evaluation, and federal law prohibits anyone under 18 from operating a forklift. Mark pedestrian walkways and enforce speed limits, follow a regular maintenance schedule, and keep detailed records of incidents and close calls.

Risk Mitigation Across Hazards

Regardless of the specific risk, there are strategies employers can implement across the organization to keep workers safe:

• Survey the facility. Identify hazards and high-risk areas, and review safety policies and procedures against OSHA standards to ensure regulatory compliance.
• Train and inspect. Train employees and supervisors on hazards and protective measures and regularly inspect machinery, ladders and PPE.
• Keep it organized. Organize and clean the workplace to minimize clutter and reduce the potential for accidents.
• Build a culture of safety. Empower employees to take charge of their safety by making sure they feel free to report concerns.

Employers who embed safety into their daily operations can help ensure a safe environment for employees. Contact us for more information on manufacturing safety.

Article Published By: Zywave, Inc.