When our team speaks to operations leaders across manufacturing and fulfillment, we've noticed a striking pattern. When asked about their proudest achievements, they rarely mention hitting record throughput numbers or exceeding order picking targets. Instead, what they are most proud about are their facility's “Days Without Accident” numbers.

In industrial operations, where heavy machinery, fast-paced environments, and physical labor intersect, prioritizing safety isn't just good practice -it's table stakes for sustainable success.

In 2023, the manufacturing industry in the United States reported 391 workplace fatalities, a slight decrease from 404 in 2022. Notably, 120 of these deaths resulted from “contact incidents,” which include situations where workers are struck by objects or caught in machinery. Additionally, “transportation incidents” accounted for 80 fatalities.

Beyond fatalities, non-fatal injuries remain a significant concern. In 2023, private industry employers reported approximately 2.6 million nonfatal workplace injuries and illnesses, an 8.4% decrease from 2022. The manufacturing sector alone accounted for 355,800 of these cases, down from 396,800 in the previous year. The incidence rate in manufacturing stood at 2.8 cases per 100 full-time equivalent workers, according to the U.S. Department of labor. 

But creating a culture of safety requires more than just posting warning signs and conducting annual training sessions (that most folks skim through anyways). It demands proactive leadership and actual commitment.

Here's what successful operations are doing right:

First, they understand that safety and efficiency aren't mutually exclusive. While requiring proper PPE or implementing detailed safety protocols might seem to slow down operations initially, these measures actually improve long-term productivity by preventing accidents and downtime.

Second, they empower employees to speak up about safety concerns without fear of repercussion. This open communication creates a collaborative environment where potential hazards are identified and addressed before they become incidents.

Third, they enforce proper attire and safety equipment requirements consistently, even when it might impact short-term productivity goals. This might mean slower movement through certain areas or additional time for equipment checks, but these "costs" pale in comparison to the potential consequences of cutting corners. For instance, while forklifts have been integral to factories and warehouses for over a century, their usage is under scrutiny due to safety concerns. Each year, around 7,500 workers suffer injuries, and nearly 100 fatalities result from forklift-related accidents. In response, companies are exploring alternatives to improve safety and productivity.

Neglecting safety isn’t just a risk to workers—it’s also financially draining. In the U.S., OSHA enforces strict penalties for safety violations. As of January 2025, the maximum penalty for serious or other-than-serious violations is $16,550 per violation, while willful or repeated violations can reach up to $165,514 per violation, according to OSHA. These fines don’t account for additional costs like legal fees, workers’ compensation claims, or the hit to a company’s reputation from repeated safety infractions.

The most successful operations understand that safety and performance aren't competing priorities - they're complementary. A safe workplace naturally becomes more efficient as employees feel secure and valued, leading to higher retention rates, improved morale, and ultimately higher productivity.