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AI in Safety Using Data to Predict, Prevent and Engage Fatality File

Worker Seriously Injured by Automated Equipment

A worker was performing maintenance near automated equipment that was part of a production system. The system was designed to operate automatically, but the worker entered the hazard zone without fully isolating the equipment. During the task, the machine activated as part of its programmed cycle and struck and pinned the worker, causing severe injuries. The investigation identified failures in hazard recognition, machine safeguarding, and energy control procedures. The incident demonstrated how advanced automated systems—whether AI-assisted or not—can create serious risks when human interaction is not properly controlled. The presence of automation increases the need for strict isolation, clear procedures, and worker awareness.

Source: Osha.gov