Electrical product manufacturing is a high-stakes industry where safety isn't just a recommendation - it's a necessity! Every day, thousands of workers in this industry are exposed to hazards, with arc flashes alone causing up to 30,000 accidents each year in the U.S. Beyond the risks of electrocution, manufacturers also deal with hazardous materials and complex systems that require active management.  

Picture this: You're in a vast factory where electrical products are being assembled - electrical circuit boards, wiring installations, and high-voltage equipment all around. Workers are handling complex machinery, and everything seems to be running smoothly. 

What if a worker accidentally gets too close to an energized circuit?

In an instant, a routine task can turn into a dangerous situation, leading to electric shocks, burns, or even worse - fatal injury. 

Unfortunately, these statistics are sobering. Electrical hazards account for 52% of worker fatalities in constructing, repairing, and cleaning settings. 

Pro Tip: As an electronic products manufacturer, meeting industry safety standards is essential for keeping your workers safe and avoiding accidents. For more detailed guidance, be sure to download our manufacturing industry safety guide.

Common Safety Hazards in Electrical Manufacturing

The hazards in electrical product manufacturing are numerous and can vary based on the processes and equipment used. However, some risks are universal across the industry.

Let’s look at some of the common safety hazards faced by electronic product manufacturers. 

1. Electrical Shocks, Burns, and Arc Flashes

Electrical shocks occur when workers come into contact with electrical currents, often due to faulty electrical cords or exposure to energized circuits. These shocks can range from mild to fatal, depending on the electrical voltages and electrical currents involved. 

In fact, according to Electrical Safety Foundation International, over the last ten years, more than 20,000 workers have been injured in workplace electrical accidents in the U.S. alone.

Arc flashes, on the other hand, occur when there is an unintended discharge of electrical energy. This can cause burns, permanent injuries, or fatalities. 

Many arc flash incidents are linked to improper use of tools around electrical panels or energized equipment. To prevent these physical hazards, ensure your team regularly inspects equipment, uses insulated tools, and follows proper lockout/tagout procedures.

2. Hazardous Materials Handling

In electrical manufacturing, you might work with combustible materials like gases and flammable liquids. For instance, improperly stored solvents can ignite, leading to catastrophic consequences. Mishandling these materials can lead to fires, explosions, or exposure to toxic substances. 

Employers must implement clear safety protocols to prevent accidents. This includes proper storage of flammable substances and training employees on how to handle hazardous materials, as explained by NASP.

3. Overhead Power Lines and Energized Equipment

Overhead power lines are a hidden danger for workers who operate cranes, ladders, or other tall equipment. 

Coming into contact with a live power line can lead to electrocution, which accounts for nearly 40% of all electrically related fatalities in the workplace. This risk is particularly high in outdoor manufacturing or assembly areas. 

To stay safe, workers should maintain a safe distance from power lines and ensure that the electrical apparatus is grounded.

Safety Standards and Regulations

Let’s say you’re walking through your electrical manufacturing facility, and you notice a technician working on an energized circuit without the proper protective gear. 

It’s an unsettling sight, isn’t it? But it’s more common than we’d like to admit. 

The good news is that strict electrical safety standards, like those from OSHA and NFPA 70E, are in place to protect workers from these high risks. These guidelines cover everything from insulated tools to ground fault circuit interrupters (GFCIs). This ensures your team is safeguarded when handling live electrical wires or overhead power lines.

But compliance isn’t just about throwing on a hard hat and calling it a day. 

For instance, OSHA requires that qualified persons routinely inspect electrical systems and that workers receive ongoing electrical safety training.  

The NFPA 70E standard specifically addresses arc flashes, which can release temperatures up to 35,000°F—hotter than the sun's surface. Without the right precautions, a single mistake could lead to serious injuries and even death!

By implementing these standards, you’re actively reducing the risk of accidents. After all, non-compliance costs aren't just monetary. They’re measured in human lives. 

Implementing a Safety Management System

Imagine this: A voltage fluctuation causes a critical wave soldering machine to shut down mid-operation. The production line grinds to a halt. Some workers instinctively reach for the equipment, risking exposure to residual heat or chemicals. Others stand idle, unsure whether to report the issue or attempt a restart.

Now rewind, the same event occurs, but this time, the moment power issues are detected, automated alerts notify key personnel. Trained operators initiate a controlled shutdown of sensitive electric equipment. Production staff swiftly move to predetermined safe zones, away from potential chemical or thermal hazards. Meanwhile, the maintenance team follows established protocols to safely assess and address the electrical anomaly. 

That’s the difference a good plan can make. 

But how to begin?

Start by identifying key risks like:

• overloaded circuit boards
• improper wiring installations
• faulty electrical cords

Once those risks are identified, you can take steps to mitigate them, such as installing ground fault circuit interrupters or conducting regular inspections of your electrical panels.

Learn more on how to develop a safety management system and what benefits it has for you!

Emergency Preparedness and Response

Electrical hazards in manufacturing facilities can escalate quickly—whether it's an electrical fault leading to a fire or an arc flash incident. Without a clear emergency response plan, these situations can turn chaotic, putting employees at risk and halting operations.

Now, the only relief in such situations would be if everyone knew exactly how to respond.

Emergencies like electrical fires, arc flashes, or even accidents involving overhead power lines can happen in a split second. Without a well-practiced response plan, the consequences can be severe. 

Take electrical fires, for example. Using the wrong fire extinguisher, such as a water-based one, can turn a small electrical fire into a deadly situation. That’s why OSHA recommends having Class C fire extinguishers specifically designed for electrical fires. 

So, what should this plan include?

What an Emergency Response Plan Looks Like

An emergency action plan should have the following:

• Clear protocols for different emergency scenarios 
• Dedicated emergency shut-off procedures that everyone is familiar with 
• Handling electrical fires caused by short circuits or faulty wiring
• Confusion and panic can make a bad situation much worse - include practices on how employees can stay calm
• Easy and direct instructions

Regular Drills and Employee Training

Having a plan isn’t enough if your employees don’t know how to execute it. This is where regular drills and training come in. 

Employees should practice what to do in an electrical emergency, whether responding to a shock, shutting down energized equipment, or evacuating in case of a fire.

According to NFPA, companies that conduct regular fire and emergency drills have 50% lower injury rates than those that don’t. 

With a strong plan and regular training, you can ensure your team is ready to act fast and stay safe when the unexpected happens.

Conclusion

Safety is a continuous effort. From protecting your team against electric shocks and arc flashes to safely handling hazardous materials. The goal is to stay one step ahead of potential dangers. 

But here’s the thing—safety isn’t a one-time task. 

Take some time to review your current safety protocols. Are they up to date? Do your employees have the training they need? 

If it’s been a while since you last did a safety audit, it’s time to put that on the to-do list.

Want a little help managing all this? SafetyIQ offers intuitive tools to help you manage safety practices effectively. We've got you covered, from audits and inspections to incident reporting and real-time monitoring. Get started today by downloading our manufacturing industry safety guide and ensure your workplace meets the highest safety standards.

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