About Us Get Involved Contact Us
Login / Register Shop
Shop
Live Chat
Skip to main content

Top risks in automotive manufacturing: Protect your workplace and team with these safety resources

Published Date
Author Jessica Bowes

Worker in an Automotive Industrial Facility Working on Vehicle Production on Automated Technology Assembly Plant.

Workplace Safety & Prevention Services (WSPS) is a not-for-profit occupational health and safety association committed to ensuring every worker goes home healthy and safe at the end of the day. As your dedicated health and safety association for the automotive manufacturing industry, we are here to help with resources and support.

The automotive industry and partners are working with WSPS to develop solutions that address the top risks in this sector. In a recent study, this group identified the top 10 risks in the automotive manufacturing industry. Find out what these risks are and how you can protect your business with these resources below.

Top 10 risks in automotive manufacturing: Resources and training

Click on a risk to learn more and access health and safety resources and training.

  1. Exposure to hazardous energy during regular operations - machine safety and lockout/tag out
  2. Noise exposure
  3. Musculoskeletal disorders (MSDs) - forceful motions, awkward postures, repetitive motion
  4. Psychologically unsafe workplace resulting in mental stress
  5. Pedestrian contact with mobile equipment (forklift, tow motor, etc.)
  6. Ineffective contractor management
  7. Exposure to hazardous energy during troubleshooting, maintenance
  8. Mobile equipment operation
  9. Contact with press (struck by/caught in)
  10. Poor interior housekeeping leading to slips and trips

Have health and safety questions? We're here to help. Contact us at 1-877-494-9777 or fill out this form and a member of our team will contact you soon.

Machine safety and lockout/tag out

Workers in car manufacturing plant.

The automotive manufacturing industry exposes workers to many types of hazardous energy including mechanical, electrical, pneumatic, and kinetic. 

If machines aren't properly safeguarded or locked out during maintenance, workers can suffer serious injuries, including amputations or even death, leading to significant costs for employers. 

To prevent these risks, employers should:

  • Review machine guarding
  • Conduct pre-shift inspections
  • Implement a clear lockout program
  • Continuously measure program effectiveness

All safety procedures and programs should also clearly outline supervisor and worker responsibilities, include proper training, and refer to any applicable legislation and standards.

Resources

Training and consulting

Back to the top of the page

Noise Exposure

Vehicle manufacturing can produce excessive noise. Effective controls are needed to prevent long-term health effects and ensure communication methods are suitable. Prolonged exposure to loud noise can cause permanent hearing damage, such as tinnitus or hearing loss. Noise can disrupt communication, concentration, and mask warning signals, potentially leading to injuries and incidents. The physical and psychological stress from noise can also reduce productivity.

To keep workers safe, workplaces should conduct noise level assessments and implement protective measures. A thorough hearing conservation program includes regular noise monitoring, worker education, and audiometric testing (hearing tests) to track health over time.

Resources 

Training and consulting

Back to the top of the page

Musculoskeletal disorders 

Automotive manufacturing workers often do repetitive tasks and handle heavy machinery, which can cause strain and injury. Poor workstation design and awkward postures add to the risk of musculoskeletal disorders (MSDs). MSDs are different aches and pains affecting the musculoskeletal system (muscles, tendons, and nerves) and make up almost half of all compensation claims in Ontario. Common MSDs include back pain, carpal tunnel syndrome, and tendonitis.  Untreated MSDs can result in lifelong disabilities.

 Employers face high costs for medical treatment and compensation, plus decreased productivity due to absenteeism. Ergonomic assessments, worker training, and automation and assistive technologies help address these challenges.

Resources

Training and consulting

Back to the top of the page

Healthy Workplaces: Mental Health and Wellness

The automotive manufacturing industry can be demanding and unpredictable, causing mental stress for workers. Poor mental health can lead to physical symptoms like headaches and psychological issues like depression, fatigue, and anxiety, resulting in more sick days, difficulty concentrating, increased incidents, and lower productivity.

Creating a healthy workplace with a positive culture, physical environment, employee well-being, psychological safety, and community involvement shows commitment to workers' overall well-being, reduces risks and costs, and enhances competitive advantage.

Maintaining worker health and safety can be achieved through effective workplace policies, strong communication and training, and fostering an inclusive environment.

Resources 

Training and Consulting

Back to the top of the page

Mobile Equipment

As automation and consumer demand grow in the automotive manufacturing industry, space constraints have become a problem in shared workspaces. Pedestrians, mobile-powered equipment, and vehicles working in a dynamic environment create a high-risk scenario. Collisions between mobile equipment and pedestrians, or between mobile equipment and fixed structures, can lead to severe or life-threatening injuries.

An organized workplace, with defined traffic flow, safe work procedures, training and supervision can reduce the risk of collisions and worker injuries, increase productivity, and have a positive impact on the bottom line.

Resources 

Safety Checklists 

Training and Consulting

Back to the top of the page

Contractor Management

As the automotive manufacturing industry expands, the need for third-party contractors has increased. Contractors are often hired for high-risk tasks, which can expose workers to additional risks if not properly identified, controlled, and communicated.

Effective contractor management involves a system of controls to ensure that contracted services support safe facility operations. Identifying potential and actual risks before contractors arrive on site is crucial to a successful program. The entire lifecycle of the contract should be addressed, including communication measures in the event of a near-miss or incident.

Resources

Training

Back to the top of the page

Slips, trips and falls

While they may seem harmless, slips, trips and falls are some of the most common causes of workplace injuries. A slip or fall can cause severe injuries, including sprains, strains, bruises, broken bones, back injuries, concussions, contusions, abrasions, and lacerations. A good housekeeping program, including quick spill clean-ups, can help reduce the risk of injury.

Working at heights, including the use of ladders and mobile access platforms, can also pose significant risks in the workplace. Develop effective work plans, policies, and programs with input from key stakeholders, including workers. This collaboration ensures safe practices are developed, applied, and maintained, which is critical for reducing risks.

Resources

Training

Back to the top of the page

Connect with an expert

If you’re ready to get started, or simply have questions about our services or approach, contact a WSPS specialist to find out more.

logo wsps white
Home How We Help Health & Safety: Resources & Tools Your Roles & Responsibilities Training & Events News & Updates
Contact Us Policies Help Centre Working at WSPS

Call us: +18774949777

Stay connected:

© Workplace Safety & Prevention Services. All Rights Reserved