Manufacturing can be a dangerous business. Moving machinery, malfunctioning equipment, heavy lifting and slips and falls can all put workers at risk. A recent study took a closer look at manufacturing injuries and, in the final report, uncovered some surprising trends.
The 2026 Travelers Injury Impact Report analyzed more than 1.2 million workers’ compensation claims from 2021 through 2025, and found that, while the number of workplace injuries are declining, when workers do get hurt, the injuries are becoming more complex and taking longer to heal.
Injured manufacturing employees missed an average of 76 workdays, up from 74, according to the report. That’s more than 15 weeks away from the job. For workers and families who depend on a regular paycheck, the impact can extend far beyond the injury itself.
The Most Common Manufacturing Injury May Surprise You
When you picture a manufacturing accident, you might imagine a worker getting caught in machinery or injured by moving equipment. Those accidents certainly happen, but the leading cause of manufacturing injuries is much more ordinary: overexertion. Overexertion accounts for 36% of manufacturing workers’ compensation claims and includes injuries caused by lifting, pushing, pulling, carrying, holding and throwing. These injuries are also costly at more than $250,000 per person.
Slips and Falls Become More Dangerous with Age
Slips, trips and falls account for another 20% of manufacturing claims and have the second-highest average cost per claim among common workplace injuries. For older employees, the danger is even greater. Workers aged 60 and older account for 18% of manufacturing injuries, and falls are the leading cause of injury. When older workers are hurt, their injuries also tend to be more complex, and they miss an average of 16 additional workdays compared with manufacturing workers overall.
New to the Job? Your Risk May Be Higher
Experience matters, too. Nearly one-third of manufacturing injuries involve employees in their first year on the job. These workers are still learning equipment, procedures and the physical demands of their positions. That vulnerability is particularly concerning when machinery is involved. “Caught-in” or “caught-between” accidents account for 10% of manufacturing claims, a greater share than in many other industries. These types of injuries spike among first-year employees.
What Should You Do If You’re Injured at a Manufacturing Job?
Manufacturing injuries can affect much more than your ability to work. A serious injury may mean surgery, rehabilitation, ongoing medical care and weeks or months without your regular income. While workers’ compensation may provide benefits for medical treatment and a portion of lost wages, depending on how an accident occurred, workers’ compensation may not necessarily be the only potential source of recovery. For example, if defective machinery, unsafe equipment or negligence contributed to your injury, you may have a potential claim.
Don’t assume that an injury is simply “part of the job.” Speaking with a leading Pennsylvania workplace injury law firm can help you understand the benefits and legal options that may be available to you.
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