Manufacturing and engineering environments are full of potential hazards, from heavy machinery to hazardous materials. According to a 2024 HSE report, over 91,000 workers in the manufacturing sector suffered from work-related ill health over the past three years. Tragically, there were 16 fatal injuries in the sector between 2023 and 2024, with a significant number caused by contact with moving machinery and being struck by objects.

These figures highlight the critical importance of maintaining high health and safety standards. It’s not just about ticking boxes to comply with the law; it’s about safeguarding lives and ensuring safe, productive working environments. Here are some of the main health hazards of manufacturing and engineering, and what health and safety measures these businesses should have in place.

Common Hazards in Manufacturing and Engineering

Manufacturing and engineering environments are inherently high-risk due to the nature of the equipment, materials, and processes involved. Understanding the most common types of hazards is vital for protecting employees and ensuring safe operations.

Physical Hazards

Physical hazards are perhaps the most visible risks on a manufacturing floor. These include moving machinery and unguarded equipment, which can cause severe injuries if not properly managed. Slips, trips, and falls are also common, often caused by wet or cluttered floors, uneven surfaces, or poor housekeeping. Prolonged exposure to high levels of noise can result in permanent hearing damage, while frequent use of vibrating tools may lead to hand-arm vibration syndrome (HAVS). Manual handling, such as lifting heavy or awkward objects, can lead to back injuries or muscle strains, especially when proper technique or assistance is lacking.

Electrical hazards 

Electrical hazards are present in almost every manufacturing and engineering setting. Faulty wiring, damaged cables, and exposed live parts can cause electric shocks or fires. Overloaded circuits and poor maintenance of electrical systems further increase the risk. A particularly dangerous situation arises when machinery is serviced without proper lockout/tagout procedures, which can result in the sudden start-up of equipment while someone is still working on it.

Ergonomic hazards 

Ergonomic hazards often go unnoticed but can have long-term consequences. Repetitive tasks, such as those performed on assembly lines, can cause repetitive strain injuries over time. Poorly designed workstations that do not support natural posture may lead to musculoskeletal disorders. Tasks that require workers to remain in awkward or static positions for long periods, such as welding or fine toolwork, also contribute to fatigue and injury.

Chemical hazards

Chemical hazards are widespread in manufacturing and engineering processes. Workers may be exposed to hazardous substances like solvents, metalworking fluids, adhesives, or welding fumes, many of which can cause respiratory issues, skin irritation, or long-term health problems. Dust from sanding, grinding or cutting can also pose inhalation risks. Under COSHH (Control of Substances Hazardous to Health) regulations, these substances must be assessed and controlled, with measures such as proper ventilation, safe storage, PPE, and training.

Fire and explosion risks

Fire and explosion risks are another major concern, especially in environments where flammable liquids, gases, or combustible dust are present. Hot work, such as welding or cutting, significantly raises the risk, particularly if carried out near flammable materials or in areas with poor ventilation. Inadequate storage of fuels and chemicals or failure to clean up spills can also contribute to hazardous conditions.

Biological hazards 

In some settings, biological hazards may arise, especially in manufacturing sectors involving food, waste, or bio-based materials. Exposure to bacteria, mould, or bodily fluids can pose health risks, particularly if sanitation protocols are not followed.

Psychological hazards

Finally, psychological hazards such as stress, fatigue, and burnout can impact health and safety just as much as physical risks. High-pressure environments, long shifts, tight deadlines, and repetitive work can all contribute to mental strain, which may in turn reduce concentration and increase the likelihood of accidents.

Identifying and mitigating these hazards through robust risk assessments, training, and safety management systems is essential. Not only does this protect employees, but it also helps create a productive, legally compliant, and resilient business.

Risk Assessments

Every workplace, particularly in manufacturing and engineering, must carry out detailed risk assessments to identify potential hazards, whether that’s machinery, chemicals, manual handling, or high-noise environments.

A thorough risk assessment evaluates the likelihood and severity of risks and identifies controls to reduce or eliminate them. This might involve physical barriers, procedural changes, or PPE (personal protective equipment). It’s not enough to conduct a risk assessment once and forget about it – assessments should be regularly reviewed and updated, especially when introducing new equipment, materials, or processes.

Site Inductions, Policies and Training

Whether you run a factory floor or an engineering workshop, clear rules, procedures, and training are essential. Every employee (and any contractors or visitors) should be given a comprehensive induction tailored to your specific site and its risks.

This induction should include:

• An overview of the facility and layout
• Identification of key hazards
• Emergency procedures and assembly points
• First aid arrangements
• Safe use of machinery and equipment
• Reporting protocols for accidents and near-misses

Formal training is a legal and moral necessity when using hazardous equipment at work. No one should operate dangerous machinery or specialist tools without first demonstrating competence through certified training. This is critical not just for their safety, but for the safety of everyone around them.

Recognising that training isn’t a one-off event is equally important. Regular refresher training should be scheduled and enforced, especially where certifications have expiry dates or new risks have emerged. This ongoing education, supported by toolbox talks and safety briefings, reinforces best practice, addresses complacency, and helps to embed a strong culture of vigilance across your workforce.

Personal Protective Equipment (PPE)

In many manufacturing and engineering settings, PPE is a final but vital layer of protection. Depending on your operations, this could include:

• Protective gloves for handling sharp or hot materials
• Eye protection for welding, grinding or working with chemicals
• Safety footwear with toe protection and slip-resistant soles
• Respiratory protection is required where dust or fumes are present
• Hearing protection in high-noise areas

PPE should always be identified through your risk assessment and communicated during induction and training. Importantly, employers must provide it free of charge and ensure it is properly maintained and replaced when necessary.

Machinery and Equipment Safety

Many workplace accidents occur when machines are misused or not properly guarded. All machinery should be:

• Suitably maintained and serviced
• Fitted with appropriate safety guards and emergency stop mechanisms
• Only used by trained and authorised personnel

Employers must also ensure that equipment complies with relevant standards, such as the Provision and Use of Work Equipment Regulations 1998 (PUWER), and that staff understand the importance of daily checks before use.

Accident and Near-Miss Reporting

All accidents – even minor ones – should be reported and recorded. Near-misses are just as important to record as they highlight risks that could easily lead to injury next time. Serious injuries, occupational diseases, and dangerous occurrences must be reported to the HSE under RIDDOR (Reporting of Injuries, Diseases and Dangerous Occurrences Regulations). But beyond legal compliance, these reports provide valuable insight that should feed into safety reviews and risk assessments. Investigating the root cause of incidents helps prevent them from happening again. Findings should be documented and used to implement changes to processes, equipment, or training.

Ultimately, health and safety in manufacturing and engineering is about more than compliance – it’s about creating a workplace culture where every individual feels responsible for their own safety and that of others. A proactive approach can reduce downtime, improve staff morale, and protect your business from legal, financial and reputational harm. Failing to uphold these standards can have devastating consequences, from life-changing injuries to criminal prosecutions. But with the right measures in place, these risks can be minimised, and a strong, safety-first culture can thrive.

If you need any assistance with health and safety compliance for your manufacturing or engineering business, please get in touch with us here or call us on 01522 527544.