Metal manufacturing is a foundational industry that also presents substantial safety risks. Each year, workers experience serious, avoidable harm, which underscores the ongoing safety challenges facilities face.

Why Mitigating Injuries Demands More Than Tradition

From crushing injuries and burns to struck-by events, the same 4 types of incidents keep showing up in metal manufacturing facilities. Despite decades of safety protocols, these incidents 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 address these events in real time.

This guide breaks down the top 4 addressable injuries in metal manufacturing, explains why they happen, and shows how combining established safety practices with video AI solutions can help keep your team safe.

The Cost of Safety Negligence in Metal Manufacturing

Safety failures in metal manufacturing can lead to hefty penalties, lawsuits, and lost business. OSHA penalties for violations can reach into the hundreds of thousands of dollars for severe incidents. These penalties are often avoidable with strong safety systems, making forward-thinking safety essential.

The top 4 addressable injuries in metal manufacturing

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 incidents are a leading cause of serious harm in metal manufacturing. The primary drivers are failure to follow lockout/tagout (LOTO), bypassed guards, and complacency—often among experienced staff. Many incidents involve hands entering pinch points, leading to serious outcomes like amputations, crushed limbs, and permanent impairments.

How video intelligence assists: AI cameras detect when workers enter designated danger zones around machinery. Timely alerts can flag unauthorized access, helping to enforce safety protocols like LOTO. Video review provides safety managers with complete context, driving targeted retraining and engineering fixes.

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 are a frequent incident, often resulting from molten metal splashes or contact with hot surfaces. Inadequate PPE, rushed procedures, and poor communication in casting and furnace areas are typical culprits. These injuries often require hospitalization, skin grafts, and long recovery times.

How video intelligence assists: AI cameras monitor hot work zones, checking for required PPE and detecting when people enter restricted areas. They can alert supervisors if someone enters a hazardous zone, aiding in the enforcement of safety protocols.

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” events are a frequent cause of serious incidents. 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 contributes: Video AI monitors identify when workers or forklifts enter designated exclusion zones, such as areas under suspended loads. On-the-spot alerts flag risky behavior, enabling teams to intervene. Footage review assists in spotting patterns—like repeated shortcuts or unsafe positioning.

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 are another prevalent type of incident. Causes? Unguarded blades, worn-out tools, and workers not wearing cut-resistant gloves. These events rarely make headlines, but they’re among the top reasons for ER visits and lost workdays.

How video intelligence aids: AI can assist in enforcing safety protocols by verifying PPE compliance and detecting when workers enter restricted zones near dangerous machinery. Over time, video analysis highlights patterns—like which machines or shifts see the most no-go zone entries—so safety teams can intervene early.

Challenges and Impact of Injuries

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, 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 entries into machine danger zones 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 improving safety, not for disciplinary purposes.
• Review and adapt: Use video analytics to spot trends, update procedures, and refine your safety program. 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 strengthens your safety program.

Ready to build a safer metal manufacturing operation?

See how Spot AI transforms your cameras into anticipatory safety tools. Request a demo to experience video AI in action and discover how it can help strengthen your safety program.

Frequently asked questions

What are the most common addressable injuries in metal manufacturing?

The most frequent addressable incidents include caught-in/crush injuries, burns from hot work, struck-by object incidents, and lacerations. These account for the majority of serious events and are directly addressable with strong safety protocols and video AI monitoring.

How can video intelligence help reduce injuries in metal manufacturing?

AI video intelligence detects unsafe behaviors—like unauthorized access to danger zones, or skipped PPE—in real time. It delivers timely alerts, supports thorough incident reviews, and assists in spotting patterns for targeted safety improvements. Video data makes it easier to enforce protocols and enhance training.

What are the biggest hurdles to implementing safety technology in metal manufacturing?

Hurdles include integrating new tech with existing systems, making sure 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 assist in documenting compliance with rules for safe work zones, LOTO procedures, PPE, and safe work procedures required by OSHA. They offer evidence for audits and incident investigations, and support ongoing improvement efforts as required by relevant OSHA standards.

Can AI cameras help reduce injury risk, or just help after the fact?

Video AI can do both. Timely alerts enable teams to intervene before incidents escalate, while post-incident reviews offer crucial context to minimize recurrences. Over time, video intelligence builds a feedback loop that strengthens 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 deliver 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 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.