In leather manufacturing, one accident can permanently alter an employee’s life. Machinery accidents are a primary cause of severe harm, making it a hazardous sector for personnel. With many work-related harm and illnesses reported annually across manufacturing, the stakes are high for both employees and business leaders.

What’s driving these numbers? The top four types of harm—amputations, lacerations, struck-by incidents, and manual handling injuries—represent daily risks in tanneries and leather shops worldwide. But here’s the catch: most of these events are avoidable.

A robust safety program is the first line of defense. But even the best procedures are only as strong as their weakest link. Advanced technology—especially AI-powered video intelligence—gives safety teams a new edge. Real-time alerts, visual evidence, and compliance monitoring enable teams to address risks before they lead to an accident.

This guide breaks down the top four types of harm in leather manufacturing facilities and explains how to lower their likelihood.

The cost of safety negligence in leather manufacturing

When safety protocols fail, the consequences go far beyond physical harm. Leather manufacturing companies have faced OSHA penalties with a median of $5,839, an average of $10,222, and a maximum penalty reaching $119,000 for a single incident. These figures reflect not only regulatory risk but also the avoidable human and financial costs tied to workplace accidents.

Penalties like these are reminders: most major incidents are avoidable. Investing in forward-looking safety—supported by tools like AI-powered video intelligence—enables organizations to avoid incidents, regulatory fines, and business disruption.

The top 4 common injuries in leather manufacturing

1. Amputations and Severe Lacerations

Scenario:
An operator feeds a hide into a splitting machine. The blade jams. In a hurry to clear it, the employee bypasses safety interlocks. The machine cycles unexpectedly, resulting in a finger amputation.

Root Causes & Impact:
Amputations account for 52% of all reported injuries in leather manufacturing, with fingers and hands most affected (Source: OSHA Leather Manufacturing Workplace Injury Data Analysis). The main drivers: missing or bypassed machine guards, production pressure leading to skipped safety steps, and inconsistent use of cut-resistant gloves. Laceration incidents occur at rates 3.2 times higher than the manufacturing average (Source: Fortune Business Insights). These events trigger hospitalizations, compensation claims, and lost productivity.

How video intelligence helps:
AI cameras can identify when people enter designated no-go zones around machinery in real time. Video evidence supports root cause analysis and retraining. Visual alerts prompt timely intervention.

2. Struck-by incidents

Scenario:
A forklift operator moves a loaded pallet near a production line. A team member steps into the path, distracted by a phone. The forklift stops in time, averting a collision.

Root Causes & Impact:
Struck-by incidents—by objects or vehicles—make up 12% of injuries, leading to fractures and, occasionally, fatalities (Source: OSHA Leather Manufacturing Workplace Injury Data Analysis). Causes include unsecured loads, unsafe pedestrian routes, and poor communication between drivers and floor personnel.

How video intelligence helps:
Video AI can spot when forklifts enter shared spaces, flag unauthorized pedestrian crossings, and issue proximity alerts. Reviewing incidents sharpens training and layout planning.

3. Manual handling injuries

Scenario:
An employee lifts a 100-lb wet hide and twists to place it on a conveyor. The employee feels a sharp pain in his back, later diagnosed as a herniated disc.

Root Causes & Impact:
Manual handling accounts for 19% of injuries, often involving lifting hides that exceed safe weight limits by 300% (Source: Global Report on Hand and Wrist Trauma). Poor workstation design, awkward postures, and understaffing increase risk. The result: musculoskeletal disorders, lost workdays, and sometimes permanent disability.

How video intelligence helps:
Video analytics can identify crowding at workstations, and footage can be reviewed to identify unsafe lifting techniques and repetitive high-risk motions. Managers can use video data to redesign workflows and deploy mechanical aids.

4. Chemical exposure and burns

Scenario:
A team loads chromium salts into an open tanning drum. A splash hits an employee’s face because their goggles were not worn correctly. Emergency decontamination is delayed, leading to a chemical burn.

Root Causes & Impact:
Chemical exposure causes 15% of occupational illnesses and 22% of incident types, mainly from splashes during manual loading (Source: National Center for Biotechnology Information). Inadequate PPE use and poor spill control are common factors. Chemical burns lead to hospitalization, long-term health issues, and regulatory scrutiny.

How video intelligence helps:
Video AI can identify missing PPE like vests and hard hats and trigger alerts to support a timely response. Footage aids in investigating exposure events and reinforcing proper protocols.

Injury-related obstacles and their impact

Here’s how each of these top 4 injuries creates obstacles—and how data and technology can assist.

How technology mitigates workplace hazards

1. Amputations and severe lacerations

Safety obstacle: Machinery accidents happen fast—often when operators bypass guards, clean jams, or take shortcuts under pressure.

Tech solution: AI-powered video platforms like Spot AI can spot when people enter designated danger zones around machinery. Real-time alerts mean supervisors can intervene before an incident occurs. After an event, video evidence clarifies exactly what happened, supporting better training and root-cause analysis.

2. Struck-By (Objects or Vehicles)

Safety obstacle: Forklift and pedestrian traffic often overlap in tight production spaces. Distraction or poor visibility can quickly lead to a collision, turning a routine operation into a serious incident.

Tech solution: AI cameras identify vehicle and foot traffic in designated zones, issuing alerts when someone enters a restricted area. Reviewing video of incidents sharpens training, reinforces safe driving policies, and justifies investments in physical barriers or traffic redesign.

3. Manual Handling Injuries (Overexertion, Ergonomics)

Safety obstacle: Heavy, repetitive lifting puts personnel at risk for serious back and joint injuries—especially if staff are rushed or poorly trained.

Tech solution: Video footage can be reviewed to identify unsafe lifting techniques and repetitive strain patterns. Managers can use this insight to schedule ergonomic training, adjust workflows, or deploy mechanical lifting aids. Video also serves to demonstrate the effectiveness of interventions over time.

4. Chemical Exposure and Burns

Safety obstacle: Manual chemical handling and inconsistent PPE use expose personnel to burns and toxic substances.

Tech solution: Video AI systems can check for missing PPE like hard hats and safety vests. They can also alert supervisors if personnel enter restricted chemical areas. Recorded footage supports emergency drills and aids in demonstrating compliance with safety protocols.

Practical implementation of safety technology

Implementing AI-powered safety in leather manufacturing integrates with your existing systems to enhance their capabilities. Most facilities have cameras installed for security. With the right software, those feeds become powerful safety tools.

Integration steps:

• Connect AI analytics to existing camera systems—no need for new hardware.

• Align alerts and reports with your current safety programs (think: toolbox talks, incident reviews, and compliance audits).

• Set up user-friendly dashboards for safety teams—without requiring specialized IT knowledge.

• Train supervisors to use video insights for coaching, not just enforcement.

When evaluating solutions, look for:

• Compatibility with your current cameras and workflows.

• Real-time alerting and easy video search.

• Support for your regulatory needs (OSHA, LWG, etc.).

• A partner that understands your industry’s unique risks.

• Simple user experience—because safety technology should support your team, not create complexity.

Improve leather manufacturing safety with a reliable partner

Safer leather manufacturing is a strategic advantage that protects your people and your bottom line. By combining proven protocols with AI-powered video intelligence, you can lessen severe incidents, boost morale, and protect your business from the costly consequences of avoidable accidents.

Curious how video AI can help lower the number of incidents and improve safety in your facility? See Spot AI in action and discover how quickly you can get started.

Frequently asked questions

How can video AI help lower the risk of machinery accidents?

Video AI can recognize when people enter designated danger zones around machinery. Real-time alerts prompt supervisors to intervene rapidly, helping lower the risk of amputations or other severe harm.

What should I consider when implementing safety technology in a leather plant?

Check for compatibility with your existing camera systems and workflows. Prioritize ease of use, real-time alerts, and customizable reports. Ensure the solution aligns with industry safety standards and is backed by a support team familiar with leather manufacturing risks.

How does video intelligence support regulatory compliance?

Video analytics provide visual evidence of safety protocol adherence and incident response. This documentation supports compliance with OSHA, Leather Working Group, and other regulatory frameworks—helping you lower the risk of costly penalties and demonstrating your commitment to employee well-being.

How does technology assist with chemical safety?

Video AI can monitor for missing PPE and spot when people enter restricted areas, alerting teams for a faster response. Footage also supports training and helps show compliance with chemical handling protocols.

What are some ergonomic risk factors in leather manufacturing and how can video assist?

Manual lifting of heavy hides, repetitive twisting, and awkward postures are leading ergonomic risks. Video footage can be reviewed to identify unsafe movements and high-risk tasks, supporting ergonomic redesigns and training programs that lessen musculoskeletal disorders.

About the author

Joshua Foster is an IT Systems Engineer at Spot AI, where he focuses on designing and securing scalable enterprise networks, managing cloud-integrated infrastructure, and automating system workflows to enhance operational efficiency. He is passionate about cross-functional collaboration and takes pride in delivering robust technical solutions that empower both the Spot AI team and its customers.