Metal manufacturing is the backbone of so many industries, but it’s also one of the most dangerous workplaces out there. Every year, thousands of workers suffer serious injuries—and too many of those are preventable. Let’s put that into perspective: metal manufacturing alone sees about 3,000 lost-time injuries and 60 equipment-related fatalities annually in the United States (Source: Bureau of Labor Statistics, 2025).
Why Injury Prevention Demands More Than Tradition
From crushing injuries to falls and burns, the same five types of incidents keep showing up in metal manufacturing facilities. Despite decades of safety protocols, these injuries persist, often because hazards change faster than most safety programs can keep up. But here’s the good news: technology—especially AI-powered video intelligence—arms safety teams with new tools to prevent these incidents in real time.
That’s what this guide is all about. We’re breaking down the top five preventable injuries in metal manufacturing, showing you why they happen, and—most importantly—how combining tried-and-true safety practices with modern video solutions can help keep your team safe.
The Cost of Safety Negligence in Metal Manufacturing
Safety failures in metal manufacturing don’t just hurt workers—they bring six-figure penalties, lawsuits, and lost business. The average OSHA penalty in this sector is $26,458, with a median of $8,395. The most severe recent penalty? $388,657 for a fatal stack collapse. Penalties are avoidable with strong safety systems. Proactive prevention is the only way forward.
The Top 5 Preventable Injuries in Metal Manufacturing: What Every Facility Needs to Know
Caught-in/Crush Injuries
Scenario: A worker bypasses lockout/tagout to quickly clear a jam in a press, believing they “know the machine.” Seconds later, a moving part crushes their hand.
Root Causes & Impact: Caught-in and crush injuries account for 28% of all incidents in metal manufacturing (Source: U.S. Bureau of Labor Statistics, 2025). The primary drivers? Failure to follow lockout/tagout (LOTO), bypassed guards, and complacency—often among experienced staff. Over 70% of amputations involve fingers, typically when hands enter pinch points. The impact is devastating: amputations, crushed limbs, life-altering trauma.
How video intelligence helps: AI cameras spot when guards are missing or workers enter danger zones. Real-time alerts flag unauthorized access to active machinery or when LOTO procedures aren’t followed. Video review gives safety managers the full story, driving targeted retraining and engineering fixes.
Falls—from Heights and Same Level
Scenario: A welder climbs atop a machine to adjust a fitting—without fall protection. A brief slip, and they tumble six feet to a concrete floor.
Root Causes & Impact: Falls account for 13.1% of injuries in metal manufacturing. Causes include climbing on equipment, poor housekeeping, and missing guardrails. Many falls lead to broken legs, hips, and even fatalities. Penalty records show fatal falls off unsecured platforms cost companies hundreds of thousands of dollars—and, more importantly, lives.
How video intelligence helps: AI video analytics monitor high-risk zones for unsafe access, missing barriers, or unapproved work at heights. Alerts can be set for unsanctioned ladder use or unauthorized presence in restricted zones. After an incident, footage reveals root causes—was it slick floors, improper steps, or a missing guardrail?
Burns (Thermal/Hot Work)
Scenario: An operator pours molten metal into a mold. A splash hits unprotected skin, causing severe burns. Or, a worker handles hot materials without realizing equipment hasn’t cooled.
Root Causes & Impact: Burns make up 12.9% of injuries, often from molten metal splashes or hot surfaces. Inadequate PPE, rushed procedures, and poor communication in casting and furnace areas are common culprits. These injuries often require hospitalization, skin grafts, and long recovery times.
How video intelligence helps: AI cameras watch hot work zones, checking for PPE compliance and unsafe proximity to molten metal. They can alert supervisors if someone enters a restricted area without heat-resistant gear or if an unsafe practice (like bypassing a safety shield) is detected.
Struck-by Objects and Material Handling
Scenario: A rigger stands beneath a suspended load, trusting a quick lift. The load shifts. Seconds later, they’re struck by a swinging beam.
Root Causes & Impact: “Struck by” injuries account for 16.6% of cases. These typically involve falling or swinging materials—cranes, forklifts, or overhead hoists. Root causes: poor communication, bypassing safe zones, or rushing material transfers. Results: fractures, crushing injuries, fatalities.
How video intelligence helps: AI video monitors identify when workers enter exclusion zones under suspended loads, or if forklifts operate unsafely. Real-time alerts flag risky behavior before disaster strikes. Footage review helps spot patterns—like repeated shortcuts or missed hand signals.
Lacerations, Cuts, and Punctures
Scenario: A worker, late for a break, skips a tool inspection. A press brake without a guard sends a metal shard flying—straight into a coworker’s hand.
Root Causes & Impact: Lacerations and punctures account for 11.6% of injuries. Causes? Unguarded blades, worn-out tools, and workers not wearing cut-resistant gloves. These injuries rarely make headlines, but they’re among the top reasons for ER visits and lost workdays.
How video intelligence helps: AI can flag missing guards, detect when hands are placed dangerously close to moving blades, and verify PPE compliance. Over time, video analysis highlights patterns—like which machines or shifts see the most near-misses—so safety teams can intervene early.
Challenges and Impact of Injuries
Injury Type | Challenges | Impact | Role of data & technology |
|---|---|---|---|
Caught-in/Crush | Complacency, bypassed procedures, LOTO violations | Amputations, fatalities, costly downtime | AI video instantly detects unsafe proximity, missing LOTO |
Falls | Unstable surfaces, missing barriers, poor signage | Broken bones, fatalities, OSHA penalties | Cameras monitor fall-risk areas, flag unsafe access |
Burns | Hot work areas, skipped PPE, fast-paced tasks | Severe burns, hospitalizations, lost time | Video audits PPE, alerts on unsafe practices |
Struck-by | Unsafe rigging, poor communication, zone violations | Major trauma, fractures, fatalities | Cameras track exclusion zones, alert on risky moves |
Lacerations | Unguarded tools, skipped inspections, missing PPE | Cuts, infections, lost workdays | AI flags missing guards, verifies PPE, reviews near-misses |
How Technology Strengthens Injury Prevention
Caught-in/Crush Injuries
Safety challenge: Workers bypass LOTO or guards, putting themselves in harm’s way.
Tech Solution: AI video platforms like Spot AI monitor machine zones for unauthorized access or unsafe proximity. Real-time alerts notify supervisors if a guard is missing, or if someone enters a danger area while a machine is active. Video records create accountability and guide targeted retraining. For example, Toyota reduced crush injuries by 40% after installing advanced guarding and monitoring systems.
Falls
Safety challenge: Unprotected elevated work, cluttered walkways, and unauthorized climbing create fall risks.
Tech Solution: Cameras spot when workers access restricted heights or use ladders unsafely. AI flags missing safety rails or barriers, and real-time alerts enable supervisors to intervene immediately. After a fall, video helps pinpoint the root cause—be it a slick surface or a missing anchorage point.
Burns (Thermal/Hot Work)
Safety challenge: Workers skip PPE, stand too close to molten metal, or ignore hot work barriers.
Tech Solution: AI cameras verify PPE compliance—heat-resistant gloves, face shields, etc.—and alert if someone enters a hazardous zone without protection. Cameras can also identify process deviations, like improper ladling or bypassed shields, allowing rapid corrective action.
Struck-by Objects
Safety challenge: Workers walk under suspended loads or ignore exclusion zones around cranes and forklifts.
Tech Solution: AI-powered cameras monitor crane and vehicle zones, alerting staff when someone enters a danger area. Video analytics can also be used to audit and improve hand signal compliance and communication between operators and ground staff.
Lacerations
Safety challenge: Missing guards, improper tool use, and lack of cut-resistant PPE lead to frequent hand injuries.
Tech Solution: AI video detects when guards are removed or not replaced, and flags when workers use their hands near blades or presses. Video review identifies repeat offenders or systemic issues, driving continuous improvement and smarter training.
Practical Implementation of Safety Technology
Integrating technology into a metal manufacturing environment doesn’t mean starting from scratch. AI video intelligence solutions like Spot AI work with your existing camera systems and safety programs. Here’s how to make it work:
Start with your critical risks: Review your injury logs and incident data. Target the top risks—crush points, fall hazards, hot work areas.
Layer AI onto what you already have: Use your current cameras, but add AI analytics for real-time monitoring and alerts.
Customize alerts: Set up notifications for specific risks—like LOTO violations or missing PPE—so your team isn’t overwhelmed.
Train your team: Make sure workers understand how video supports—not replaces—them. Show how footage is used for learning and prevention, not blame.
Review and adapt: Use analytics from video to spot trends, update procedures, and keep improving. The best systems make your safety program smarter over time.
When choosing a tech solution, look for ease of integration, customizable alerting, clear reporting tools, and support for compliance documentation. Your goal: technology that fits your workflow, empowers your team, and closes the loop on injury prevention.
Ready to Build a Safer Metal Manufacturing Operation?
Every injury prevented means a worker goes home safe—a win for your team and your bottom line. The right mix of safety culture, best practices, and technology gives you the edge. Spot AI partners with safety leaders to help you turn your cameras into proactive safety tools. Want to see how? Book a consultation and start making your facility safer today.
Frequently asked questions
What are the most common preventable injuries in metal manufacturing?
The most common preventable injuries include caught-in/crush injuries, falls, burns from hot work, struck-by object incidents, and lacerations. These account for the majority of serious incidents and are directly addressable with strong safety protocols and modern video monitoring.
How can video intelligence help reduce injuries in metal manufacturing?
AI video intelligence detects unsafe behaviors—like missing guards, unauthorized access to danger zones, or skipped PPE—in real time. It provides instant alerts, supports thorough incident reviews, and helps spot patterns for targeted prevention. Video data makes it easier to enforce protocols and improve training.
What are the biggest challenges to implementing safety technology in metal manufacturing?
Challenges include integrating new tech with existing systems, ensuring alerts are actionable (not overwhelming), and building trust with staff. Solutions like Spot AI make integration straightforward and focus on supporting—not replacing—human-led safety programs.
How does AI-powered video support OSHA compliance?
Video analytics help document compliance with machine guarding, LOTO, PPE, and safe work procedures required by OSHA. They provide evidence for audits and incident investigations, and support continuous improvement efforts as required by standards like 29 CFR 1910 Subpart O.
Can AI cameras really prevent injuries, or just help after the fact?
AI video can do both. Real-time alerts help stop incidents before they escalate, while post-incident reviews provide crucial context to prevent recurrences. Over time, video intelligence builds a feedback loop that continuously improves safety outcomes.
How do I choose the right safety technology for my facility?
Look for solutions that integrate with your existing cameras, offer customizable alerts, and provide clear, actionable data. Focus on technologies that support your safety goals and empower your team—rather than creating extra work or tech headaches.
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.
