Every year, machinery manufacturing facilities across the U.S. report over 18,000 serious injuries—including amputations, crush incidents, and lacerations—and 800 worker fatalities (Source: OSHA, 2025). Despite decades of progress, these numbers remain stubbornly high. Most of these injuries share a common thread: they’re preventable.

From entanglements in running machines to falls off maintenance platforms, the risks are real—and the consequences can be life-altering. What’s more, the same top five injuries keep showing up in OSHA reports, costing companies not just in fines, but in lost productivity and team morale.

But here’s the good news: a combination of proven safety protocols and new technology like AI-powered video analytics can dramatically reduce these incidents. In this guide, we’ll walk through the top five preventable injuries in machinery manufacturing, what causes them, and—most importantly—how a smarter, tech-supported safety approach can keep your people out of harm’s way.

The Cost of Safety Negligence in Machinery Manufacturing

When safety takes a backseat, the penalties go beyond medical bills and lost workdays. OSHA fines for major violations in machinery manufacturing average $9,006, with the median at $5,839 and the highest recent penalty nearly $97,786. These numbers don’t include indirect costs like retraining or lost output—which often exceed fines by a factor of four or more (Source: NARFA, 2025).

By investing in robust safety programs—and leveraging real-time video intelligence for early detection and intervention—manufacturers can keep these penalties (and their root causes) off their record.

The Top 5 Preventable Injuries in Machinery Manufacturing: What Every Plant Needs to Know

1. Amputations and Crush Injuries

Scenario: A worker reaches into a jammed press to clear debris. The machine hasn’t been locked out. In seconds, a hand is caught, resulting in traumatic amputation.

Root Causes & Impact:

• Unguarded moving parts responsible for 47% of serious incidents (Source: OSHA National Emphasis Program, 2025).

• Manual bypassing of safety systems—often to “keep production moving”—cited in 41% of cases.

• New employees are 3.2 times more likely to be injured due to lack of training.

• Amputations made up 27.8% of all injuries, with 415 cases reported in the last cycle.

How video intelligence helps: AI-powered cameras can instantly flag when a guard is removed, or when hands enter hazardous zones while machines are running. Supervisors receive real-time alerts—enabling immediate intervention before tragedy strikes.

2. Fractures and Traumatic Brain Injuries (from Falls and Struck-By Incidents)

Scenario: During a quick maintenance check on an elevated platform, an experienced operator skips the harness. A missed step leads to a fall—ending in a fractured leg and hospitalization.

Root Causes & Impact:

• 22% of fatalities occur during equipment maintenance falls.

• 55% of experienced operators neglect fall protection for short tasks.

• Struck-by injuries stem from falling parts or loads—like an overhead crane dropping a component.

• Fractures (especially hips, legs, and skull) are among the top five reported injuries.

How video intelligence helps: AI cameras can detect when workers enter elevated areas without harnesses, or when loads are improperly rigged. Automated alerts prompt supervisors to intervene—stopping unsafe behaviors before someone gets hurt.

3. Cuts, Lacerations, and Avulsions

Scenario: A machine operator clears a jam from a high-speed cutter without powering down or donning protective gloves. A split-second slip leads to deep lacerations and possible partial amputation.

Root Causes & Impact:

• 18% of incidents stem from blade contact and unguarded cutting zones.

• 29% of operators admit to removing safety guards to fix jams.

• Cuts and lacerations are often severe, many requiring surgery or leading to permanent disability.

How video intelligence helps: Video analytics can monitor for removed guards, unsafe hand positioning, and compliance lapses. When a worker enters a danger zone or bypasses safety measures, the system triggers an alert, helping teams intervene before injuries escalate.

4. Crushing and Struck-By Injuries (Material Handling Equipment)

Scenario: A worker loading steel tubing with a forklift is caught between the load and a rack due to a communication breakdown. The result: crushing injuries to legs and feet, sometimes requiring amputation.

Root Causes & Impact:

• Forklifts, cranes, and hoists are frequent sources of struck-by and crush injuries, especially to lower limbs.

• Poor visibility, lack of spotters, and rushed material handling compound the risk.

• Crushing incidents often involve severe trauma, hospitalizations, and sometimes death.

How video intelligence helps: AI cameras track vehicle and pedestrian movement, flagging near-misses and dangerous proximity in real time. With clear video evidence, supervisors can retrain teams and redesign workflows to keep people out of harm’s way.

5. Burns, Electrocutions, and Environmental Exposures

Scenario: An electrician is troubleshooting a CNC machine with faulty wiring. There’s no arc-flash risk assessment, and the panel is energized. A sudden arc flash causes severe burns and hospitalization.

Root Causes & Impact:

• 33% of facilities lack proper arc-flash assessments.

• Contact with hot surfaces and exposure to chemicals are also leading causes of second- and third-degree burns.

• Burns and electrocutions account for 12% of incidents, with many requiring extensive treatment and resulting in fatalities.

How video intelligence helps: Video analytics can monitor for PPE compliance (e.g., arc-flash suits), unsafe access to electrical panels, and even flag when workers are in restricted areas. Fast alerts mean teams can intervene before an incident becomes a statistic.

Challenges and Impact of Injuries

How Technology Strengthens Injury Prevention in 2025

Amputations and Crush Injuries

Safety challenge: Unguarded machines and bypassed protocols are still a leading cause of life-changing injuries.

Tech Solution: AI video analytics send instant alerts when guards are removed or when hands break a virtual “safety line” while equipment is active. Spot AI empowers safety teams to spot unsafe actions, review footage, and drive accountability—without sifting through hours of video.

Falls and Traumatic Injuries

Safety challenge: Shortcuts—like skipping harnesses for “quick” jobs—lead to costly and sometimes fatal falls.

Tech Solution: Video intelligence can detect when workers enter elevated zones without visible harnesses or when ladders/platforms are misused. Real-time alerts allow supervisors to intervene before a risky shortcut becomes a life-altering injury.

Cuts, Lacerations, and Avulsions

Safety challenge: Operators often remove guards or reach into machines to clear jams, especially under production pressure.

Tech Solution: Cameras equipped with AI can detect missing guards and unsafe hand placement, alerting teams instantly. Reviewing video of past near-misses lets supervisors retrain teams and address workflow bottlenecks that encourage risky behavior.

Crushing and Struck-By Injuries

Safety challenge: Forklift and crane operations are fast-paced, with poor visibility and rushed communication leading to severe injuries.

Tech Solution: AI cameras monitor pedestrian and vehicle zones, flagging dangerous proximity and unauthorized access. Near-miss analytics help identify hotspots and drive process changes—like redesigning aisles or adding visual cues.

Burns, Electrocutions, Environmental Exposures

Safety challenge: Missing PPE and unsafe electrical work put lives at risk, especially during maintenance or troubleshooting.

Tech Solution: Video intelligence checks for PPE compliance, monitors access to restricted panels, and can even support root-cause analysis in incident investigations. Teams can spot patterns—like recurring panel access violations—and reinforce training where it’s needed most.

Practical Implementation of Safety Technology

• Integration with existing safety programs: Modern video intelligence platforms like Spot AI work with your current camera systems. You don’t need to rip and replace—just add smarter analytics on top.

• Customizable to your risks: Identify your injury hotspots—unguarded presses, high-traffic forklift lanes, elevated work platforms—and target those with video monitoring and real-time alerts.

• Supports—not replaces—your team: AI doesn’t replace human oversight. It empowers your safety managers with instant insights, so they can take action before someone gets hurt.

• Evaluating solutions: Look for platforms that are easy to deploy, provide search-friendly footage retrieval, and allow you to create custom safety “rules” that fit your workflows.

• Continuous improvement: Use incident and near-miss video to retrain teams, refine processes, and make a real impact on safety culture.

Ready to Make Your Plant Safer? Book a Safety Consultation Today

Every injury prevented is a family spared, a team kept whole, and a business kept on track. The right safety technology doesn’t just catch issues—it empowers your team to lead the way in injury prevention. If you’re ready to take the next step, book a consultation with Spot AI. Let’s partner to build a safer, smarter machinery manufacturing workplace—where your people are always the priority.

Frequently Asked Questions

What are the most common injuries in machinery manufacturing, and how can they be prevented?

The top injuries include amputations, crush injuries, fractures from falls, cuts/lacerations, and burns or electrocutions. Prevention starts with strict machine guarding, enforced lockout/tagout, proper PPE, and robust training. Technology like AI video analytics adds a real-time layer of prevention, flagging unsafe behaviors and helping supervisors intervene faster.

How can video intelligence integrate with our existing safety programs?

AI-powered video platforms, such as Spot AI, typically work with your current camera infrastructure. They overlay analytics and real-time alerting, without requiring you to replace hardware. They support your safety team by making it easy to review incidents, spot trends, and enforce compliance.

What challenges might we face when implementing safety technology in a manufacturing environment?

Common challenges include resistance to change, data privacy concerns, and ensuring the technology fits real workflows. Overcoming these requires clear communication, involving frontline staff in solution design, and choosing user-friendly platforms that don’t disrupt established operations.

Are there compliance issues to consider with video-based safety systems?

Yes. Ensure your video system complies with OSHA guidelines for workplace monitoring and privacy laws. Work with your legal and HR teams to draft clear policies on camera use, footage retention, and employee notifications.

How can AI video analytics help reduce material handling injuries?

AI cameras track the movement of forklifts, cranes, and workers. They can flag dangerous proximity, unauthorized access, and near-misses, helping supervisors redesign workflows and reinforce safe practices before a serious incident occurs.

What are best practices for training teams to work with new safety technology?

Start with transparent communication about the “why”—emphasize prevention and empowerment, not surveillance. Offer hands-on demos, encourage questions, and use real incident footage (with privacy protected) for practical learning.

About the Author

Joshua Foster
‍IT Systems Engineer, Spot AI

‍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.