A vehicle-related injury in manufacturing costs – on average – around £74,000, according to to our analysis of HSE figures.
CT Safety Barriers’ analysis of workplace injury figures found that this cost is the equivalent of nearly two workers’ average salary in manufacturing.[1]
Injuries falling – but still costing millions
While the number of employees injured in manufacturing environments due to being struck by a vehicle is steadily dropping year-on-year, the total cost per year of such injuries still stands at around £17.9m.
The HSE figures[2] for 2014 to 2023 show that the total number of reported non-fatal injuries caused by vehicles has fallen by 15.5% over the period – from 296 to 250.
In 2021/22, when the last full set of data was available, the cost of all injuries in manufacturing was £815m.
As 2.2% of all injuries in manufacturing were due to vehicle collisions, this works out as a cost of £17.9m in 2021/22.
With 241 vehicle-related injuries that year, that makes the average cost per injury of £74,000.
This cost is usually split between three sources:
- Individuals through lost wages or impact on their lives
- Employers through lost hours
- Government / taxpayer through compensation payments
The majority of this cost is borne by the employees (58%), with government (22%) and employers (18%) bearing less than half of that cost.
This means that, on average, each employee loses out on around £42,920 in lost earnings, while the government has to pay £16,320, and the employer loses out on £13,320.
Fatalities by vehicle collisions in manufacturing
While the number of actual deaths caused by being struck by a vehicle in a manufacturing environment is relatively low, there were still 15 deaths since 2014.
In total, there were 454 vehicle-related deaths in this period across all sectors, meaning manufacturing accounts for 3.3% of all vehicle-related deaths.
In 2017/18, there were 4 fatalities for this reason in manufacturing, while the other years have either 1 or 2 deaths.
Two-fold costs to accidents
CT Safety Barrier’s founder Chris Caunce said: “Reducing accidents involving vehicles in manufacturing environments is a win-win.
“It not only means fewer accidents – that can have a huge impact on the person’s life and income – but it can also help employers to save money.
“One of the best ways to help keep moving vehicles separate from workers and pedestrians is through Armco safety barriers.
“These not only help provide a clear demarcation for vehicles, but also reduce the effect of any collision on both the people involved and the vehicles.”
Manufacturing injuries and deaths: the statistics
The HSE statistics on workplace injuries show:
- Total number of workplace injuries dropping: Since 2003/04, the total number of workplace non-fatal injuries has dropped from 965 to 561.
- Fatal injuries by sector: There were 15 fatal injuries in the manufacturing sector during the 2022/23 period, down from 18 in 2014/15.
- Fatal injuries by type: Being struck by a moving vehicle accounted for 18% of fatal injuries in 2022/23.
- RIDDOR incidents: Manufacturing accounts for about 16% of all reported dangerous occurrences across all sectors, as per Reporting of Injuries, Diseases and Dangerous Occurrences Regulations.
- Slips, trips, and falls: These incidents constitute about 29% of all non-fatal injury reports in the sector.
- Machinery accidents: Accidents involving machinery represent about 22% of the non-fatal injuries in manufacturing.
- Handling injuries: Handling, lifting, or carrying incidents account for 20% of non-fatal injuries in manufacturing.
- Employment figures and risks: Manufacturing employs only about 7% of the UK workforce but accounts for a higher proportion of both fatal and non-fatal injuries compared to other sectors.
Armco safety barriers in a manufacturing environment
While safety legislation and practices are improving, there’s still some way to go to reduce injuries by vehicles in manufacturing settings.
Armco barriers are often used in manufacturing situations to:
- Prevent accidents in warehouses: Armco barriers are installed in areas with high vehicle movement, such as forklift operations, to prevent accidents. They are strategically placed in front of shelving units and between valuable equipment to absorb impacts and minimize damage.
- Separate traffic and pedestrian areas: These barriers are used to create clear divisions between areas of foot traffic and vehicle operations within the workplace. This helps in preventing collisions and ensuring the safety of pedestrians.
- Protect infrastructure: Armco barriers serve as protective shields for buildings, equipment, and other critical infrastructure within industrial sites against vehicle impacts.
[1] https://www.reed.co.uk/average-salary/average-manufacturing-salary