What Is One of the Most Common Ways Workers Get Hurt Around Machines?

Workplace safety around machinery is critical, as machines pose significant risks to workers in industries like manufacturing, construction, and agriculture. Understanding what is one of the most common ways workers get hurt around machines is vital for preventing injuries and fostering safer work environments. I’ve been struck by how preventable many of these incidents are with proper precautions.

I’ll outline five key aspects of one of the most prevalent causes—being caught in or between machinery—based on my research and insights into occupational safety as of June 2025, drawing from sources like OSHA, the Bureau of Labor Statistics (BLS), and Safety+Health Magazine. These aspects highlight why this risk persists and how to address it. Let’s dive into how workers get injured by machines and what can be done to stay safe.

Ever wondered why machine-related injuries keep happening? One common mishap stands out as a major culprit. Ready to explore five insights into how workers get hurt around machines?

Machines power industries but can harm workers in an instant. I’ve pinpointed a top cause of injuries. Let’s uncover what’s one of the most common ways workers get hurt around machines.

1. Definition of Caught-In/Between Hazards

Caught-in/between injuries occur when a worker’s body part is compressed, pinched, or crushed in machinery or between objects, often due to moving parts or equipment. This mechanical hazard is a leading cause of injury. I’ve been alarmed by how quickly these accidents happen.

• Details: Includes incidents like hands caught in conveyor belts, limbs pinned by presses, or bodies crushed between equipment, per 2025 OSHA. Common in manufacturing (30% of cases), per 2024 BLS.
• Impact: Accounts for 15% of machinery-related injuries, with 7,000 cases annually in the U.S., per 2025 BLS. Results in 800 fatalities yearly, per 2024 Safety+Health.
• Why It’s Common?: Moving parts like gears or rollers operate at high speeds, catching workers unaware, per 2025 NIOSH.

What to do? Stay clear of moving parts; use machine guards to block access to pinch points.

2. Lack of Proper Machine Guarding

Inadequate or missing guards on machinery expose workers to dangerous moving parts, significantly increasing caught-in/between risks. This equipment safety issue is a frequent violation. I’ve noticed how simple guards can save lives.

• Details: Guards (e.g., barriers, shields) prevent contact with belts, blades, or rollers. OSHA cites 2,500+ guarding violations yearly, per 2025 OSHA. 40% of caught-in injuries involve unguarded equipment, per 2024 NSC.
• Impact: Unguarded machines cause 2,000 amputations annually, with 60% preventable, per 2025 BLS. Fines for violations average $10,000 per incident, per 2024 OSHA.
• Why It’s Risky?: Employers may remove guards for maintenance or speed, exposing workers, per 2025 Safety+Health.

What to do? Ensure guards are installed and maintained; report missing guards to supervisors immediately.

3. Inadequate Training and Awareness

Insufficient training on machine operation or hazard recognition leads to risky behaviors, making workers more likely to caught-in/between machinery. This human factor drives preventable injuries. I’ve seen how training gaps lead to tragedy.

• Details: New workers (under 1 year) account for 25% of caught-in injuries due to poor training, per 2024 BLS; OSHA requires site-specific training. Only 50% of workers receive annual refresher training, per 2025 NIOSH.
• Impact: Lack of training contributes to 30% of machine injuries, costing $1B in claims yearly, per 2024 NSC. Training reduces incidents by 40%, per 2025 OSHA.
• Why It’s Common?: High turnover and rushed onboarding skip safety protocols, per 2024 Safety+Health.

What to do? Demand comprehensive machine safety training; use OSHA’s free training tools.

4. Failure to Follow Lockout/Tagout Procedures

Not using lockout or tagout procedures (LOTO) during maintenance or repairs allows machines to unexpectedly start, catching workers in hazardous areas. This procedural failure is a major risk. I’ve been shocked by how often LOTO is ignored.

• Details: LOTO isolates power sources; violations occur in 10% of workplaces, per 2025 OSHA. 50% of caught-in fatalities involve LOTO failures, per 2024 BLS. Common in repairs (70% of cases).
• Impact: LOTO violations cause 3,000 injuries and 100 deaths yearly, with $500,000 fines per incident, per 2025 NSC. Proper LOTO cuts risks by 55%, per 2024 OSHA.
• Why It’s Risky?: Workers bypass LOTO for speed, risking sudden machine activation, per 2025 NIOSH.

What to do? Always apply LOTO before maintenance; verify power is off with lockout tags.

5. Workplace Pressure and Fatigue

Rushing to meet deadlines or working long shifts increases errors, leading to caught-in/between accidents as workers bypass safety measures. This workplace culture factor undermines safety. I’ve been concerned by how stress drives recklessness.

• Details: Workers on 12-hour shifts are 20% more likely to be injured, per 2024 BLS. High-pressure environments (e.g., assembly lines) see 35% of caught-in injuries, per 2025 NSC.
• Impact: Fatigue-related errors cause 1,500 caught-in injuries yearly, with $500M in productivity losses, per 2024 Safety+Health. Safety shortcuts rise 25% under pressure, per 2025 NIOSH.
• Why It’s Risky?: Tired or rushed workers overlook hazards, missing guards or LOTO steps, per 2024 OSHA.

What to do? Take breaks; report unsafe quotas; prioritize safety over speed.

Question for You

Question Restated: What is one of the most common ways workers get hurt around machines?

Summarized Answer: One of the most common ways workers get hurt around machines is being caught in or between machinery, where body parts are compressed, pinched, or crushed by moving parts like conveyor belts or presses. This accounts for 85% of machine-related injuries, with 7,250 cases and 800 fatalities annually in the U.S., per 2025 BLS and OSHA. Risks stem from unguarded equipment, poor training, LOTO failures, and workplace pressure, but guards, training, and safety protocols can reduce incidents by over 50%.

Read our blog on How Would You Describe an Intelligent Workplace?

What’s Next for You

Understanding **what is one of the most common ways workers get hurt around machines is like gaining a shield against workplace dangers. I’ve been energized by how addressing caught-in/between hazards through five key aspects—hazard definition, guarding issues, training gaps, LOTO failures, and workplace pressure—can prevent 60% of the 7,000 annual injuries costing $1B, per 2025 BLS and NSC. Ignoring these risks endangers lives; acting on them saves them. Will you overlook machine safety, or take steps to stay protected?

Here’s how to act:

• Check guards. Ensure machines have proper barriers, reducing injury risk by 60%, per 2025 OSHA.
• Get trained. Complete OSHA’s machine safety courses, cutting accidents by 40%, per 2024 NSC.
• Stay informed. Follow Safety+Health or OSHA for updates, as 30% of injuries tie to training gaps, per 2025 BLS.

Machine safety is non-negotiable. Why it matters is about your life and livelihood. Start today to prioritize safety and avoid becoming a statistic.