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:  

1. Safety protocols keep people alive and uninjured.

2. Safety protocols improve workforce productivity.

3. Safety protocols are the best way to manage risk. Safety protocols consistently minimize risks and liability, leading to substantial long-term cost savings.  

4. Safety protocols are required by law. Compliance with OSHA regulations are mandatory, and non-compliance may result in massive fines and even jail time.  

5. 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.  

WORK SAFELY WITH NRTC AUTOMATION

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services.

Contact us today to learn more about how we can help you meet your production goals.

How Industrial Equipment Can Help You Make Safety a Priority

Thousands of work-related injuries and deaths can be prevented each year with industrial equipment. 

Manufacturing can be a dangerous industry to work in. 

Machinery is constantly in motion and chemicals of all kinds are used to manufacture products and materials. 

OSHA created standards to protect workers from these potential hazards, and with industrial equipment, manufacturers can align their facilities with these standards. 

Learn more about OSHA’s standards for manufacturing and how industrial equipment can help you meet your safety goals below. 

Safety in industrial environments 

What safety standards are set in place? 

OSHA, or the Occupational Safety and Health Administration, is a governmental body dedicated to workplace safety standards in the United States.  

Prioritizing safety is important for all industries, but it is especially necessary in construction and manufacturing due to the dangers present in the workplace. NRTC Automation upholds safety as the number one priority in all our services. 

Listed below are the top safety standards that all manufacturing facilities are expected to use: 

• Lockout tagout (LOTO): LOTO are procedures used to prevent equipment from running during repairs and maintenance as well as to prevent spills and leakage of hazardous materials. A lockout device will keep unaware individuals from attempting to use to machinery or materials. A tag will include information about who created the tag and the time of placement. A thorough inspection must be performed if the tag is to be removed. 

• Permit-required confined spaces (permit space): Workplaces with spaces that are too small for people but large enough for workers to perform tasks is considered a confined space. These spaces require permits from OSHA for workers to access. Examples of confined spaces are pipelines, tunnels, and tanks. They may have some of the following characteristics: exposed live wires, heat stress, converging walls or sloping floors, and more. 

• Personal protection equipment (PPE): PPE is gear worn by workers to protect them from injury and death. There are different PPE designed for specific hazards, including heat, impact, optical radiation, chemicals, and dust. Common PPE worn by manufacturing workers include safety goggles, face shields, and hardhats. 

• Machine guards: Using machine guards is especially important in manufacturing where machines are constantly working around human workspaces. There are over 800 deaths per year that could have been prevented with a machine guard. There are several parts that needed to be guarded on a machine, such as the point of operation and around any blades. Each piece of equipment is unique in what machine guards it requires. 

• Warning signs: OSHA requires certain warning signs to be used in areas where there are hazards such as dangerous chemicals or heavy machinery. They must be able to be universally understood, like using a bright yellow color for caution signs and red for danger signs. Manufacturing facilities must also contain signs for first aid stations and emergency eye wash stations. 

• Employee compliance: Last but certainly not least, employee compliance is an important part of maintaining a safe facility. Employees must first be aware of the safety standards required by OSHA and the employer must provide the necessary PPE and other tools to keep employees safe. Then, employees must conform to safety standards to protect themselves and others from harm. OSHA inspectors can inspect a facility without warning to ensure safety standards are being met. 

With these safety standards set in place, manufacturing workers can perform their jobs without fear of injury or worse, creating a productive and efficient facility. 

How industrial equipment can help you make safety a priority 

Industrial equipment can do more than increase throughput and capacity in your facility. It can also help you prioritize safety for your workers. 

1. INDUSTRIAL EQUIPMENT CAN MAKE WORKSPACES MORE ERGONOMIC. 

According to OSHA, workspaces lacking ergonomics are a significant cause of musculoskeletal disorders (MSD) and injuries; in fact, they are the most frequently cited cause of lost productivity. 

Using industrial equipment to enhance the ergonomics of your employees’ workspaces is key to preventing potentially long-term injuries. For example, a turntable provides easy access to materials or equipment while helping workers waste less energy and time on extra movement. 

Check out iGAM's Fibromat Heavy Load Positioning Turntable for a great deal on safety equipment for your employees. 

2. INDUSTRIAL ROBOTS CAN HANDLE THE REPETITIVE TASKS. 

Industrial robots are designed specifically for repetitive tasks like material handling, welding, and more.  

Repetitive tasks are another source of MSD and injuries. For example, material handling can cause shoulder problems that affect workers for a lifetime.  

Additionally, repetitive tasks can be dull and cause workers to drop their attention, which can not only cause problems for product quality and productivity, but it can also pose serious risk to the workers’ health. 

By adding an industrial robot to your facility, you can increase productivity while protecting your workers from unnecessary harm. 

3. INDUSTRIAL ROBOTS CAN ALSO HANDLE THE HEAVY LIFTING. 

Industrial robots, such as this R-2000IC-210F FANUC robot, have a payload capacity of several hundred pounds. Some robots can even lift several tons! 

With an industrial robot, you can ensure that heavy materials, parts, products, or equipment are expertly handled without fear of harming your employees. 

4. ACCESS EQUIPMENT PREVENT FALLS. 

Finally, industrial access equipment such as stairs, lifts, platforms, and ladders assist manufacturing workers with getting to hard-to-reach places without putting themselves in danger. 

Falls are the leading cause of death in construction. Along with the right safety gear, access equipment can prevent tragedy in the workplace. 

Visit iGAM to shop for stairs, ladders, and platforms for your employees. 

Get on top of safety in your facility 

Creating and maintaining a safe work environment requires consistent effort and vigilance. However, it’s well worth it when your employees are satisfied knowing their safety is secured.  

Work with NRTC Automation and iGAM to protect your employees, no matter what size, phase, or industry you’re in. 

SCHEDULE A FREE CONSULTATION WITH NRTC AUTOMATION 

NRTC Automation is dedicated to providing high-value industrial automation and manufacturing equipment solutions to all our customers.  

From decommissioning and tear out to industrial robotic training services to custom flexible work cells, NRTC is the key to integrate your workplace. With personalized training and custom-built designs, NRTC Automation is the destination for all your industrial automation and manufacturing equipment services. 

Visit NRTC Automation today for full-service solutions to improve productivity in your facility. 

The History of OSHA

OSHA, or the Occupational Safety and Health Administration, is a governmental body dedicated to workplace safety standards in the United States. 

Because of OSHA, tens of thousands of lives have been saved from tragedy in the workplace since the 1970s. The regulations set by OSHA ensure that workers are protected and that employers are held responsible to provide safety education and equipment. 

Prioritizing safety is important for all industries, but it is especially necessary in construction and manufacturing due to the dangers present in the workplace. NRTC Automation upholds safety as the number one priority in all our services. 

Learn more about OSHA’s history and its regulations for construction and manufacturing below! 

History of OSHA

Before OSHA 

Before the 1970s, there was very little legislation on safety in the workplace.  

In fact, prior to the workers’ compensation movement in the late nineteenth and early twentieth centuries, workplace safety was basically nonexistent. Once workers’ rights became a conversation in Congress, laws to protect workers started to go into effect. 

However, the laws for workplace safety were still negligible. In 1970, there were over 14,000 fatalities due to work-related accidents and injuries. After years of what could have been preventable deaths and injuries, President Lyndon Johnson proposed legislation for workplace safety. 

OSHA’s Beginnings 

President Richard Nixon signed the Occupational Safety and Health Act in December of 1970, establishing a new era of workplace safety. The law officially went into effect in April of 1971.  

OSHA struggled at first to create clear and comprehensive laws for workplace safety until the Assistant Secretary of Labor, Dr. Eula Bingham, arrived. She improved OSHA by discarding trivial laws and clarifying necessary standards to manage serious health and safety situations. 

Dr. Bingham met adversaries in big business and Congress since regulations could hurt economic activity, but she was backed by President Jimmy Carter to pursue workplace safety for American citizens. 

Since Dr. Bingham’s leadership, OSHA has been improving its laws and regulations to protect the rights and safety of people in the workplace. 

Safety in Construction and Manufacturing 

From childcare to food prep, OSHA’s laws cover safety for all industries. 

The construction and manufacturing industries are especially prone to accidents and fatalities due to heavy machinery and the dangerous heights that workers scale in order to perform their jobs. 

These are the basic safety regulations that should be maintained in the workplace in order to be compliant with OSHA’s standards: 

• Employee Education and Compliance Assistance: Workers should know their rights, as well as the safety procedures they must follow to protect themselves and others from harm. The employer should provide this information before the worker begins employment and offer assistance for compliance, if necessary. 

• Fair and Effective Enforcement: Employers should enforce OSHA’s regulations to ensure that workers continue to prevent accidents in the workplace. Enforcement may include regular refreshers on OSHA’s safety standards or giving warnings to workers who were not complying with OSHA’s regulations. 

• Effective Hazard Management: Hazards such as falls, repetitive motion injuries, collapses, and more should be approached from every angle to protect workers from injuries or fatalities. This could include using safety net systems, immediately correcting any slippery areas on stairs, or marking toxic chemicals with signage to alert workers about danger. 

• Personal Protective Equipment (PPE): Employers should provide any and all PPE to workers, and workers are expected to wear PPE in the workplace. PPE includes hard hats, high-visibility gear like bright yellow vests, steel-toe boots, gloves, and other safety equipment. 

NRTC Automation follows these guidelines closely with safety signs and perimeters, branded safety gear, and a project manager to enforce OSHA guidelines with each tear out. Our workers can focus on your equipment and facility with peace of mind knowing their safety is prioritized. 

OSHA Today 

Compared to the tens of thousands of fatalities before OSHA (and considering the fact that workplace accidents were not accurately recorded), the number of fatalities and injuries have dropped markedly due to OSHA’s standards. 

In 2009, there were less than 5,000 fatalities recorded in the workplace. The mandates set by OSHA for safety may have prevented over 10,000 deaths from avoidable accidents and even more injuries. 

Workers can be more productive and efficient because they feel safe and secure. By complying with OSHA regulations, employers and employees can enjoy a safer workplace.  

SAFETY IS NRTC AUTOMATION’S PRIORITY. 

At NRTC Automation, we take OSHA’s standards seriously. We follow OSHA safety guidelines in every tear out and with each service. Our team members wear bright and branded safety gear, set up safety perimeters and signage, set up a plan for safe and efficient tear outs, and more. 

Whether we are building your parts in our warehouses or tearing out your facility, NRTC Automation follows all safety precautions to provide professional and reliable services. 

For more information on NRTC Automation’s commitment to safety, or to learn more about how we can serve your industrial and automation needs, contact us today.