9 Most Common Accidents in Automotive and Vehicle Manufacturing

Accidents in automotive and vehicle manufacturing can lead to severe consequences, including injuries, production delays, financial losses, and damage to reputation.

Identifying and understanding the most common types of accidents is crucial for implementing effective safety measures and preventing future incidents. In this blog, we'll explore nine of the most prevalent accidents encountered in automotive and vehicle manufacturing facilities.

Slip and Fall Accidents

Slip and fall accidents are among the most common workplace incidents in any industry, including automotive manufacturing. These accidents can occur due to wet or oily floors, cluttered walkways, inadequate lighting, or improper footwear. Employees may slip, trip, or fall, leading to injuries ranging from minor bruises to serious fractures or head trauma.

Machinery Accidents

The extensive use of heavy machinery and equipment in automotive manufacturing poses a significant risk of accidents. Employees can get caught in moving machine parts, crushed by equipment, or injured while operating machinery without proper training or safety precautions. Machinery accidents often result in severe injuries or fatalities, highlighting the importance of strict safety protocols and regular maintenance checks.

Struck-By Accidents

Workers in automotive manufacturing are at risk of being struck by vehicles, parts, tools, or materials moving within the facility. These accidents can occur due to inadequate signage, blind spots, distracted driving, or failure to maintain a safe distance from moving objects. Implementing measures such as designated walkways, warning signals, and training on safe material handling practices can help mitigate struck-by accidents.

Chemical Exposure

Automotive manufacturing involves the use of various chemicals, including lubricants, solvents, paints, and cleaning agents. Employees may be exposed to these hazardous substances through inhalation, skin contact, or ingestion, leading to respiratory problems, skin irritation, chemical burns, or long-term health issues such as cancer or organ damage. Proper ventilation systems, personal protective equipment (PPE), and employee training on chemical handling and storage are essential for minimizing the risk of chemical exposure accidents.

Overexertion Injuries

The physical demands of automotive manufacturing tasks, such as lifting heavy components, repetitive motions, and working in awkward positions, can result in overexertion injuries. These injuries include strains, sprains, muscle tears, and musculoskeletal disorders like carpal tunnel syndrome or tendonitis. Ergonomic assessments, employee training on proper lifting techniques, and implementing mechanical aids or ergonomic workstation designs can help prevent overexertion accidents.

Electrical Accidents

Electrical hazards are prevalent in automotive manufacturing facilities, where workers interact with electrical equipment, wiring, and machinery. Accidents such as electric shocks, burns, or fires can occur due to faulty wiring, exposed electrical components, or improper use of electrical tools. Regular inspections, electrical safety training, and adherence to relevant codes and standards are essential for preventing electrical accidents in the workplace.

New call-to-action

Falling Objects

Objects falling from heights, such as shelves, storage racks, or overhead cranes, pose a significant risk to workers in automotive manufacturing plants. Employees may be struck by falling tools, parts, or materials, leading to head injuries, fractures, or lacerations. Implementing proper storage systems, securing loads, and wearing appropriate head protection can help reduce the risk of falling object accidents.

Vehicle Collisions

In facilities where vehicles are operated, such as assembly lines or warehouses, the risk of vehicle collisions is inherent. Employees may be involved in accidents while driving forklifts, trucks, or other industrial vehicles, especially in congested areas or during reversing maneuvers. Implementing traffic management plans, installing mirrors or cameras for visibility, and enforcing safe driving practices can help prevent vehicle collision accidents.

Burns and Fires

The presence of flammable materials, welding operations, and hot surfaces in automotive manufacturing facilities increases the risk of burns and fires. Employees may suffer burns from hot machinery, welding sparks, or chemical reactions, while uncontrolled fires can cause extensive property damage and endanger lives. Implementing fire prevention measures, providing fire extinguishers and emergency response training, and conducting regular fire drills are essential for mitigating the risk of burns and fires in the workplace.


Preventing accidents in automotive and vehicle manufacturing requires a comprehensive approach that addresses various safety hazards and encourages a culture of safety among employees. By identifying the most common types of accidents and implementing appropriate preventive measures, organizations can create a safer working environment, protect their workforce, and enhance operational efficiency. Stay tuned for our next blog, where we'll explore strategies for preventing safety incidents 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

Training your mind to associate safety in the workplace with reporting

Workplace safety is a paramount concern for organizations across all industries. Ensuring a safe...

3 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

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

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.