March 20, 2025
Comprehensive training and a robust safety culture are key to preventing electrocution risks in manufacturing settings.
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A 2024 industry report revealed that many manufacturing employees feel unsafe due to inadequate safety training and outdated procedures.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.
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