According to the US Bureau of Labor Statistics (BLS), work-related injuries in the manufacturing sector contributed to 5,190 fatalities in 2021. This marked a 9% increase from the 4,764 fatalities recorded in 2020. The fatal injury rate of 3.6 fatalities per 100,000 full-time workers in 2021 marked the highest increase since 2016.

According to another analysis, the preventable death rate increased to 3.1 (per 1,00,000 workers) in 2021. These statistics suggest that despite the growing awareness of worker safety, the manufacturing sector continues to suffer from occupational injuries and fatalities. Cuing back to the BLS census on fatal occupational injuries, one worker died from work-related injuries in 2021 – every 101 minutes.

To this end, what are the major risks to worker safety in the manufacturing sector? Let’s discuss. 

Top 5 Risks to Worker Safety in Manufacturing

Before talking about how manufacturers can ensure worker safety, here’s a look at the 5 leading risks to workers in this industry:

1. Physical Injuries

In any manufacturing facility, workers can suffer physical injuries due to accidental falls, slips, and trips. This poses a serious risk to workers working at elevated heights. Besides that, manufacturing equipment and industrial debris also increase the risk of physical injuries.

To deal with this risk, manufacturers often provide safety tips to workers. Additional measures include immediate clearance of industrial debris and the creation of safe walkways for workers inside facilities.

2. Lack of Machine Guarding

Hazardous manufacturing equipment like cutters, radial drills, and power pressers can also pose a major risk to industrial workers. Safety hazards in the form of flying chips, electric sparks, and rotating parts can result in hand injuries or even amputation.

Without machine guarding measures, manufacturers cannot protect their workers from these hazards. Machine guards act as a line of defense that protects workers from the dangers of heavy machinery.

3. Repetitive Stress Injuries

Repetitive stress injuries, also known as cumulative trauma disorders, typically affect the worker’s musculoskeletal and nervous systems. These injuries arise from tasks that involve repetitive motion with arms, wrists, and feet. Despite all the automation, human workers continue to perform multiple tasks and operations manually.

4. Electrical Hazards

Manufacturing workers also face the risk of electrical hazards when working within industrial facilities. This can arise due to exposed wiring, unsecured electrical panels, or improper installation of electrical equipment. Electrical equipment can cause fires that can pose a serious risk to workers’ lives.

5. Chemical Exposure

Industrial workers regularly expose themselves to dangerous chemicals present in cleaning solutions, flammable substances, and battery acids. Besides this, workers can suffer from occupational diseases caused by air contamination, chemical gases, and smoke. Industrial workers can also encounter long-term health problems like asthma, bronchitis, and other respiratory problems.

How Computer Vision Technology Can Ensure Worker Safety

Computer vision (CV) technology powered by AI can help prevent workplace accidents in manufacturing facilities. For instance, by integrating machine learning with CV technology, manufacturers are notified of any safety risks and unsafe behaviors.

Most manufacturing facilities have installed cameras to monitor their workers’ movement and maintain safety standards. However, this is insufficient when a human must manually monitor the camera feeds. An AI-powered CV system can automate this task through continuous monitoring of the facility’s entry & exit points along with high-risk areas. Whenever there are any safety violations, CV systems can notify the floor managers or other peer employees working on the same premise.

Similarly, CV technology can improve workers’ safety by checking if they are wearing protective equipment like helmets, safety glasses, and protective vests at all times. Easy to configure, CV systems can detect and identify a range of safety devices present in the manufacturing facility. It can send real-time alerts to workers or operators whenever there is any deviation from safety standards.

How can CV technology prevent occupational hazards? CV models can recognize a major chemical spill – or even a gas leak that is invisible to the human eye. Regarding workplace injuries, CV technology (enabled by connected cameras) can immediately report injured workers so that they are provided with immediate medical care. Besides, advanced CV models can also detect improper postures among employees lifting heavy weights or working at a height.

How Can We Help?

Worker safety is among the leading concerns, particularly in the manufacturing domain. Safety issues can reduce workplace productivity and attract heavy fines and penalties. Manufacturers can no longer rely on manual safety measures to keep their workers safe and active. Digital technologies like AI-powered computer vision can help in reducing worker injuries and fatalities.

With its expertise in AI-powered computer vision technology, KamerAI has enabled manufacturers to improve and maintain their workplace safety standards. For example, KamerAI’s hard hat detection solution uses camera data to enforce employee safety regulations.

Want to know how computer vision technology can improve your workers’ safety? Connect with our consultants today for a profound insight into the technology’s prowess for worker safety.