Electrical hazards are one of the most dangerous and often overlooked risks in manufacturing. Many workers assume that factory and production-controlled environments, established protocols, and modern equipment eliminate the possibility of electrocution from high-voltage equipment. However, data proves otherwise.
The manufacturing industry is among the top five industries with the highest number of electrical fatalities. According to the Electrical Safety Foundation International (ESFI), 74% of workplace electrical fatalities occur in non-electrical occupations, indicating that workers outside of traditional electrical roles face significant risks. Additionally, 28% of all workplace electrical fatalities take place on industrial premises, reinforcing the need for heightened safety awareness in manufacturing environments.
Electrocution incidents in manufacturing often occur unexpectedly due to heavy-voltage equipment and arc-flash injuries. Arc flashes, which are sudden releases of electrical energy through the air due to a fault, can result in severe burns, neurological damage, and fatalities. These incidents often are caused by improper procedures, lack of training and PPE usage, and unauthorized personnel interacting with electrical systems.
Beyond the human impact, electrical incidents can result in significant financial and reputational consequences for businesses. The BLS reported 2.6 million nonfatal workplace injuries and illnesses in 2023—the latest data available—with more than 900,000 cases leading to time away from work. These disruptions hinder operations, lower productivity, and drive insurance costs higher, making proactive safety measures essential for maintaining efficiency and financial stability in manufacturing environments.
A 2024 industry report revealed that many manufacturing employees feel unsafe due to inadequate safety training and outdated procedures. This signals a pressing need for leadership to address training gaps and reinforce electrical safety measures as soon as possible.
The reality is that most electrocution accidents are preventable. When organizations and workers disregard or aren’t trained on proper safety protocols, they expose themselves to unnecessary risks. It’s the responsibility of leadership to create and enforce a culture of electrical safety by implementing industry best practices that include proper training and firm adherence to safety regulations.
How to Create a Culture of Electrical Safety
Electrical safety in manufacturing extends beyond compliance with regulations—it requires a proactive, company-wide commitment to safety. Risks can be significantly minimized when workers at all levels understand proper procedures, are encouraged to take action, and follow established safety protocols. In addition, many insurers offer risk management programs designed to evaluate safety procedures, identify hazards, and recommend necessary training improvements across your manufacturing production environment.
Building a culture of electrical safety involves a structured approach that includes training, employee empowerment, daily reinforcement, and access to control measures. Below are four key steps to ensuring a safe manufacturing environment.
1. Prioritize Training & Awareness
Comprehensive safety training is one of the most effective ways to reduce electrical accidents. A single, one-time training session is insufficient; instead, ongoing and updated education is necessary to ensure employees stay informed about the latest safety protocols.
Ongoing Training: Electrical safety training should be an ongoing process, with regular refresher courses to address emerging risks and reinforce best practices. Companies should incorporate annual safety assessments to identify training gaps and make necessary updates.
Focus on New Employees: New employees are particularly vulnerable to workplace injuries. Data shows that workers in their first month on the job are over four times more likely to have a lost-time claim due to injury than workers there over one year, and 28% of workplace injuries occur among employees with less than one year of service. Since newer workers may not be fully aware of the electrical hazards on the job site or with the equipment, targeted onboarding programs that include dedicated electrical safety and lockout/tagout (LOTO) training can help reduce risk.
LOTO (lockout/tagout) Training: LOTO procedures prevent equipment from being powered on during maintenance. Improper use of LOTO is a major contributor to electrocution incidents. Regular training on how to properly apply and follow LOTO procedures can prevent fatal mistakes in manufacturing environments.
2. Empower Workers to Speak Up
One of the most overlooked aspects of workplace safety is ensuring that staff feel comfortable reporting hazards. Many workers hesitate to raise concerns about safety due to fear of retaliation or lack of confidence that their concerns will be addressed.
Encourage Open Communication: Manufacturing leaders should establish open communication channels, such as anonymous reporting systems or safety meetings where employees can voice concerns without fear of consequences.
Promote a No-Retaliation Policy: Workers should be assured that raising safety concerns will never lead to disciplinary action. Encouraging workers to report unsafe conditions or near-misses allows organizations to take corrective action before an accident occurs.
3. Make Safety a Daily Priority
Daily reinforcement of electrical safety through communication, training, and leadership involvement can make a significant difference in reducing risks.
Daily and Weekly Safety Briefings: Holding brief safety meetings at the beginning of shifts keeps electrical hazards top of mind and allows employees to discuss any potential or observed risks.
Signage and Visual Reminders: Clear safety signs near high-voltage areas, electrical panels, and breaker boxes can remind workers of potential hazards and proper procedures.
Leadership’s Role in Safety: Managers and supervisors should actively demonstrate safe behavior by following protocols and using personal protective equipment (PPE) when necessary. Employees are more likely to take safety seriously when they see their leaders prioritizing it.
4. Strengthen Safety Procedures and Access Controls
Many electrical accidents in manufacturing occur due to unauthorized or improper interactions with electrical systems. Strict access controls and safety measures will reduce risks.
Restrict Access to Electrical Equipment: Only trained and authorized personnel should have access to electrical panels, breaker boxes, and high-voltage machinery. Limiting access prevents untrained staff from making mistakes and causing accidents.
Prevent Unsafe Resetting of Breakers: Electrical incidents can happen when workers reset breakers without first identifying the cause of the issue. Electrical faults should be diagnosed by qualified personnel before resetting any circuits.
Address Arc-Flash Risks: Studies indicate that improper maintenance, lack of PPE, and failure to de-energize equipment contribute to arc-flash incidents. Strict enforcement of safety gear usage and proper de-energization procedures can mitigate these risks.
Enforce LOTO Compliance: Ensuring that workers adhere to proper lockout procedures can prevent machinery from being accidentally energized during maintenance.
Manufacturing a safe future
Manufacturing environments present unique challenges when it comes to electrical safety, but electrocution incidents are preventable when organizations take a proactive approach. Understanding the risks, addressing training gaps, and fostering a strong culture of safety are crucial to reducing workplace fatalities and injuries.
By implementing ongoing safety training, empowering workers to speak up, integrating safety into daily operations, and enforcing strict procedural controls, manufacturing leaders can significantly mitigate electrical hazards. Leadership plays a vital role in ensuring that electrical safety is a shared responsibility and a fundamental value within the organization, not just a compliance requirement.
By prioritizing education, communication, and strict adherence to best practices, manufacturing companies can create a safer working environment for all members of their team and prevent tragic accidents before they occur.
