The 4 Most Common Industrial Injuries and How to Avoid Them

OSHA lists injury and illness statistics similar to those reported by the NSC, many of which come from the manufacturing sector, with men more accident-prone than women.

Overall, illnesses have declined significantly since the National Safety Council’s 2022 report, although hearing loss, skin disorders and respiratory conditions still make up their fair share of OSHA cases. (Hearing and respiratory protection go far to minimize those, however, while safety gear such as gloves, together with proper cutting fluid maintenance, help to reduce rashes and other types of skin irritation.)

Preventing Manufacturing Accidents

Injuries, meanwhile, continue to dominate manufacturing’s Days Away from Work, Job Restriction, or Transfer (DART) category. Here are ways to avoid some of the most common:

Slips, Trips and Falls

Floors should be kept clean and dry, with well-lit working areas free of any tripping hazards. If hazardous areas exist, mark them with safety signs, and if those areas are high above the ground (a mezzanine, for instance), guardrails should be present. Evaluate whether slip-resistant footwear is called for; otherwise, install safety treads in slippery spots. And for workplaces where scaffolds, ladders and aerial lifts are needed, make certain to use personal fall arrest systems and inspect them regularly.

Struck-By Incidents

OSHA uses the term “struck-by incidents” as an umbrella description for objects, equipment and vehicles hitting people. Anyone who owns or rents forklifts should certify them and their drivers, training them on blind spots, load limits and stability. Then, make sure to keep pedestrians separate from forklift traffic with no-walk zones and high-visibility clothing as appropriate. If there’s a chance anyone in the facility might be struck by falling objects, hard hats are in order; the same goes for safety glasses to avoid being hit by metal chips from machining equipment or flying debris in a cabinet shop.

Caught-In, Caught-Between Accidents

This category refers to being trapped inside, or crushed by, equipment. It’s the reason why CNC machine tools are equipped with door interlocks, and manual equipment like engine lathes and grinders have spindle/wheel guards. Whatever the machinery, don’t disable or uninstall these safety devices. Operators should never wear loose clothing or ponytails around any power equipment—wood chippers, excavators, trenching machines or saws of any kind—to keep from accidentally getting pulled into it.

Exposure to Harmful Substances

Thanks largely to OSHA and other safety-focused agencies, workers today face far less risk from hazardous chemicals than they once did. Even so, care is still needed. Oils, solvents, adhesives, cleaners, etc., should be stored in approved containers with proper labeling. Depending on the chemical, workers and storage areas need adequate ventilation systems—for many machine shops, this means installing mist collectors. In some worksites, respirators or face masks or even a powered air-purifying respirator might be needed.

Finally, don’t forget worker training, for these situations and others, including electrical safety, waste disposal, fire prevention, repetitive motion injuries, lifting and overexertion, and the nemesis of anyone working with metal, wood, plastic, paper or meat for a living: cuts.

“Finding and fixing hazards before they cause injury or illness is a far more effective approach” than responding afterward, OSHA says. “Doing so avoids the direct and indirect costs of worker injuries and illnesses and promotes a positive work environment.”

What are your best tips for avoiding common industrial accidents? Tell us in the comments below.