Important OSHA Stats and Figures in Manufacturing
Learn these important OSHA statistics to help keep your employees safe.
The manufacturing environment is often unpredictable and dangerous; workers may come in contact with heavy machinery, toxic substances, and even electrical hazards. Safety in the manufacturing industry is essential and safety standards reduce countless preventable injuries and even deaths each year.
The Occupational Safety and Health Administration (OSHA) is a regulatory body dedicated to creating and maintaining workplace safety standards within the United States. It was established in 1970 to assure safer conditions for Americans.
The Bureau of Labor and Statistics reported around 14,000 work-related deaths in 1970. In contrast, the number of work-related deaths in 2018 was 5,250, despite the doubling of the U.S. workforce over that time period.
Although this progress is substantial, there’s still more work to be done to reduce workplace injury and fatalities. In 2019 alone, the manufacturing industry reported 846,700 injuries, which represents 6.6 cases per 100 full-time workers or 15 percent of all nonfatal injuries and illnesses in the private industry sector.
Benefits of having a safe workplace for employees
Safety in a manufacturing environment goes beyond checking boxes. Detailed and comprehensive manufacturing safety approaches are important for both workers and the company for a variety of reasons:
Safety protocols keep people alive and uninjured.
Safety protocols improve workforce productivity.
Safety protocols are the best way to manage risk. Safety protocols consistently minimize risks and liability, leading to substantial long-term cost savings.
Safety protocols are required by law. Compliance with OSHA regulations are mandatory, and non-compliance may result in massive fines and even jail time.
Safety protocols reduce costs. Safety incidents are very expensive and may include costs such as workers’ compensation, repairing broken equipment, regulatory penalties and legal fees, and decreased productivity. OSHA estimates that every one dollar invested in safety had a sixfold return on investment.
Preventing accidents in manufacturing
In order to realize its mission, each year OSHA releases a set of guidelines for manufacturing practices as well as facts and figures related to common violations.
SLIPS AND FALLS
Because of moving machinery, forklifts, and other obstacles in a manufacturing environment, manufacturing workers are especially prone to trips and falls. OSHA maintains industry regulations to prevent trips and falls.
OSHA guidelines aim to protect against:
Slips: a loss of balance as a result of limited friction between shoes and the walking surface (in other words, loss of traction).
Common causes of slips include:
Wet product or spills on smooth walking surfaces including water, mud, grease, oil, and even blood.
Dry product or spills, such as dusts, powders, granules, wood, or plastic wraps.
Heavily polished flooring or waxed surfaces such as concrete, marble, or ceramic tile
Sloped walking surfaces or ramps without traction
Ladders
Trips: a loss of balance caused by forward momentum after a foot hits an object.
Common causes of trips include:
Uncovered hoses, wires, or extension cords across walkways
Clutter and obstacles in walkways
Open cabinets or desk drawers
Changes in elevation or levels (such as unmarked steps or ramps)
Mounting/dismounting vehicle equipment
Falls: a loss of balance as a result of movement outside the center of balance. OSHA further segments falls into falls at the same level/surface and falls to a lower level.
According to the Bureau of Labor and Statistics (BLS), most falls are related to same-level walking surfaces. The manufacturing sector accounts for 16 percent of all injuries resulting from same-level falls.
To protect against slips, trips, and falls, OSHA guidelines mandate:
All passageways and stairways must remain free from clutter and obstacles. Handrail surfaces must be able to sustain at least 200 pounds and be finished to prevent snagging.
Businesses must maintain clean, dry floors that are free from debris and clutter. If there are surfaces that are used for water or wet processing, they must have proper drainage and mats and dry areas need to be present.
Adequate lighting is required in all walkways including stairs, hallways, and ramps.
MACHINERY GUARDING ACCIDENTS
Machines and other moving parts have the potential to cause workplace injuries including crushed limbs, amputations, burns, and even blindness. OSHA named machine guarding accidents among its top ten list of frequently cited violations and accidents.
According to OSHA, workers who operate machinery suffer 18,000 amputations, lacerations, crush injuries, and abrasion per year. Use of machines such as power saws, shears, presses, fans, conveyor belt, and palletizers are regulated. OSHA requires protection mechanisms to be in place, known as machine guarding.
Machine guarding can include barriers, light curtains, and two-hand trips and most frequently applies to the point of operation (the location where work is performed). While it’s not possible to guard some machines at multiple points, OSHA recommends secondary controls like alarms and fences.
Costs associated with workplace injuries in manufacturing
Beyond the pain and suffering of human beings, a single manufacturing safety incident may have huge cost implications for your company including:
Regulatory fines: As of 2021, OSHA penalties for violations may cost up to $13,494, however penalties for willful or repeat violations cost upwards of $134,927. Moreover, failure to correct the violation by its deadline could result in additional penalties of $13,494 per day.
Increased industrial insurance premium: each workers’ compensation incident will raise insurance premiums.
Ancillary costs associated with training replacement workers, damaged reputation, and potential lawsuits.
According to Liberty Mutual’s Workplace Safety Index, nearly a third of the same level falls represent 21 lost workdays. When factoring in all ancillary costs associated with a safety incident using OSHA’s $afety Pays website, the true cost of an accident may be several thousand times greater than the cost of preventative measures.
Safety plans can have long-lasting benefits and returns, for businesses as well as employees. Safety plans can maximize workplace productivity while minimizing risk.
OSHA training and guidelines are good keystone practices, however the most successful manufacturing workplaces create a culture of safety that goes beyond regulation.
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