hazards in manufacturing industry | TECH EHS

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Manufacturing safety hazards are multifaceted, ranging from physical dangers posed by machinery and materials to ergonomic and environmental risks. Despite advances in safety protocols and technologies, the industry faces significant challenges in mitigating these dangers. Understanding the most common and critical safety hazards is essential for developing effective prevention and response strategies.

With the advent of new technologies, the manufacturing industry is set to improve efficiency, quality of work, and employee safety. It is growing from strength to strength, developing capabilities from real-time equipment maintenance to virtual design and opening an utter scope of possible applications.

Safety performance has become an essential differentiator in these industries – all share and communicate a joint commitment to providing a workplace that has constituted and implemented an up-to-date risk and hazard management plan. In manufacturing, factory hazards are spread and visible all over the plant, so focusing on a safer workplace is vital. Safe and healthy workplaces are an asset to a business, which helps it operate more efficiently, and companies can enjoy a healthy bottom line.

Once you know what are the hazards in a factory and what common hazards in the manufacturing industry prevail in manufacturing units—their know-how becomes necessary to undertake preventive measures. TECH EHS safety animation aims to address those risks and health hazards in the manufacturing industry to allow a better understanding of their significance in safety.

Safety Hazards In The Manufacturing Industry

1. Fall From Heights

Fall protection violations remain on top of the list of safety violations in the year 2019 – 6010 violations were reported[1]. Even a fall from six feet can prove deadly when landing on the wrong body part or surface. Spinal, head, or neck injuries are common, regardless of height, and can leave a worker severely disabled or fatal. An informed choice of equipment and knowledge can safeguard workers from potential falls—proper PPE, comprehensive training, instructions, and guidance are hence necessary.

2. Electrical safety

When risks and industrial hazards in the manufacturing industry are properly identified, manufacturing hazards like working around electricity on a job site can be made safe. Common electrical manufacturing hazards that put industrial workers at risk are overhead powerhead lines, damaged tools and equipment, improper grounding and exposure to electrical parts, damaged insulations, and wet conditions.

TECH EHS animated movie serves as a guide for performing work near electrical equipment and helps apply best electrical safety practices.

3. Lockout Tagout-Tryout (LOTOTO)

LOTOTO has been considered one of the safest methods of isolating equipment prior to its repair and maintenance. Its main purpose is to protect employees from accidental re-energization of equipment that has the potential to cause injuries or fatalities. As this is imperative in ensuring a safe lockout, thorough training on the method and usage of the appropriate devices is essential.

4. Machine Guarding

OSHA statistics claim that workers who operate and maintain machinery suffer approximately 18,000 amputations, lacerations, crushing injuries, abrasions, and over 800 deaths per year. Poor machine guarding has a direct correlation with these statistics. Hence, guarding workers against hazards caused by moving parts within the equipment or machines is necessary to stay compliant, achieve maximum efficiency and productivity, and, most importantly, for employee well-being.

5. Powered Industrial vehicles (PIVs)

Known as forklifts, power jacks, lift trucks, and reach trucks, these are the most common vehicles seen on worksites, often used to raise, lower, or remove small and large objects on pallets or in boxes, crates, or other containers. Incidents involving PIVs that result in injuries and damage to public property are primarily due to a lack of training or working within an instruction-based environment. Many workers who use the equipment for longer durations tend to take shortcuts around safe procedures. Training, worker protection, awareness of the immediate surroundings, and correct handling of loads are some preventive measures that can help employees around these versatile pieces of equipment.


TECH EHS safety animation can walk you through the risks and health hazards in the manufacturing industry at a workplace, creating awareness and emphasizing safety for all. Remember, preventive steps for all the above hazards and escalating health and safety in manufacturing consume a little extra time—regular inspections, effective training, or appropriate PPEs. However, that extra time can avert a potential incident and prevent an on-site worker from experiencing painful downtime.

So now, if it is to be noticed what are two common workplace hazards within the manufacturing sector? We know that there are not two but five or more things that the manufacturing sector needs to be safe of!


1. OSHA Reveals Top 10 Violations for 2019 at NSC Congress and Expo: National Safety Council, published September 2019, accessed on 21 Jan 2020. Find online here.

Frequently Asked Questions(FAQ)

Always use proper guarding on machines, follow lockout/Tagout procedures during maintenance, and ensure employees receive training on the correct equipment operation.

Employees should receive comprehensive training on electrical safety, including safe handling practices, emergency procedures, and recognition of electrical hazards.

SDS provides detailed information on the properties, hazards, handling, and emergency measures related to chemicals. They are crucial for understanding how to work with and respond to chemical exposures safely.

4.2 min read Views: 140 Categories: Safety Animation

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