15 Most Common Safety Risks in Automotive and Vehicle Manufacturing

Safety is a top priority in automotive and vehicle manufacturing to protect workers, prevent accidents, and maintain operational efficiency. Identifying and addressing safety risks is essential for creating a secure working environment and ensuring the well-being of employees.

In this blog, we'll explore fifteen of the most common safety risks encountered in automotive and vehicle manufacturing facilities.

Machinery Hazards

Machinery hazards pose significant risks to workers involved in operating, maintaining, or repairing manufacturing equipment. These hazards include moving parts, pinch points, and rotating machinery that can cause crushing, amputation, or entanglement injuries if safety protocols are not followed.

Falls from Heights

Working at elevated heights, such as on platforms, scaffolds, or ladders, is common in automotive manufacturing for tasks like maintenance, installation, or inspection. Falls from heights can result in serious injuries or fatalities if proper fall protection measures are not in place or utilized correctly.

Chemical Exposure

Exposure to hazardous chemicals, such as solvents, lubricants, or cleaning agents, poses health risks to workers in automotive manufacturing facilities. Inhalation, skin contact, or ingestion of these chemicals can lead to respiratory issues, skin irritation, or long-term health effects if proper handling and safety precautions are not observed.

Electrical Hazards

Electrical hazards are prevalent in automotive manufacturing facilities, where workers interact with electrical equipment, wiring, and machinery. Improper use of electrical tools, damaged wiring, or lack of proper grounding can result in electric shock, burns, or fires if safety procedures are not followed.

Ergonomic Strain

Repetitive motions, awkward postures, and manual lifting tasks in automotive manufacturing can lead to musculoskeletal disorders (MSDs) such as carpal tunnel syndrome, back pain, or tendonitis if ergonomic risks are not addressed through proper workstation design, training, and ergonomic assessments.

Heat and Cold Stress

Extreme temperatures, whether hot or cold, present risks of heat stress or cold stress to workers in automotive manufacturing. Prolonged exposure to high temperatures can lead to heat exhaustion, while exposure to cold environments can result in hypothermia or frostbite if appropriate temperature controls and protective measures are not implemented.

Confined Space Hazards

Working in confined spaces, such as tanks, vessels, or equipment compartments, poses risks of suffocation, engulfment, or exposure to hazardous atmospheres if proper confined space entry procedures and safety precautions are not followed.

Noise-Induced Hearing Loss

Excessive noise levels generated by machinery, equipment, or processes in automotive manufacturing can cause noise-induced hearing loss if proper hearing protection is not worn, and noise control measures are not implemented.

New call-to-action

Struck-By and Caught-In/Between Hazards

Workers in automotive manufacturing are at risk of being struck by moving vehicles, objects, or equipment, as well as being caught in or between machinery or structures if proper safety precautions, such as barriers, warning signs, or machine guarding, are not in place.

Manual Material Handling Injuries

Manual material handling tasks, such as lifting, carrying, or pushing heavy objects, can result in strains, sprains, or back injuries if proper lifting techniques, ergonomic controls, and mechanical aids are not utilized.

Slips, Trips, and Falls

Slippery floors, cluttered walkways, or uneven surfaces in automotive manufacturing facilities pose risks of slips, trips, and falls if proper housekeeping, maintenance, and slip-resistant flooring are not maintained.

Fire Hazards

The presence of flammable materials, welding operations, or electrical equipment in automotive manufacturing facilities increases the risk of fire hazards if proper fire prevention measures, such as fire detection systems, fire extinguishers, and employee training, are not in place.

Lack of Personal Protective Equipment (PPE)

Failure to use appropriate personal protective equipment (PPE), such as safety goggles, gloves, or respiratory protection, exposes workers to risks of injuries or exposure to hazards in automotive manufacturing processes.

Chemical Spills and Releases

Improper handling, storage, or disposal of hazardous chemicals in automotive manufacturing facilities can result in spills, leaks, or releases, leading to environmental contamination, exposure risks, and emergency situations if proper containment and spill response procedures are not implemented.

Lack of Emergency Preparedness

Inadequate emergency response plans, evacuation procedures, or employee training in automotive manufacturing facilities can result in delays or confusion during emergencies, increasing the risk of injuries or fatalities if timely and effective response measures are not in place.


Identifying and addressing safety risks in automotive and vehicle manufacturing requires a comprehensive approach that involves risk assessments, hazard identification, employee training, and implementation of appropriate controls and safety measures. By proactively addressing common safety risks, organizations can create a safer working environment, protect workers' health and well-being, and maintain operational efficiency in automotive manufacturing facilities.

Are you looking for a tool to monitor nonconformities or any other issues in your organisation? Falcony | Observe ticks all the boxes for issue management, is easy to customise, enables real dialogue and is a lot more. 

Falcony free trial

We are building the world's first operational involvement platform. Our mission is to make the process of finding, sharing, fixing and learning from issues and observations as easy as thinking about them and as rewarding as being remembered for them.‍

By doing this, we are making work more meaningful for all parties involved.

More information at falcony.io.

Related posts

9 Common Near Misses in Waste Management and How to Avoid Them

Most waste management companies are battling with environmental responsibility and sustainability...

4 min read

7 Most Common Safety Risks in the Chemical and Petrochemical Industry

The chemical and petrochemical industry plays a crucial role in supplying essential products to...

Safety Management
4 min read

9 Common Near Misses in Warehousing and Distribution

Safety can often be second in priorities next to efficiency in warehousing and distribution...

Safety Management
6 min read

Involve your stakeholders to report

At Falcony, we create solutions that multiply the amount of observations and enable our customers to gain greater understanding of what’s going on in their organisations, areas of responsibility and processes.