I. General information
(i) large accident situations
There were no larger accidents in the mechanical industry in 2025, and the number of larger accidents decreased by 1 and the number of deaths by 8 compared to 2024。
(ii) distribution of industries
According to the national economic industry classification (gb/t 4754-2017), of the nine main categories of the machinery industry, the top five production safety accidents in 2025 were in the metal industry, in general equipment manufacturing, specialized equipment manufacturing, automobile manufacturing, electrical machinery and equipment manufacturing, accounting for 91 per cent of the total accidents。
(iii) type of accident
According to the classification of accidents and accidents of employees in enterprises (gb 6441-1986), by type of accident, the top five types of accidents in the mechanical industry in 2025 were mechanical injuries, object strikes, high drops, electric shocks and other injuries, with accidents and deaths accounting for 86. 3 per cent of the total number of accidents. Compared to 2024, the type of accidents with high frequency in the mechanical industry has not changed。
Ii. Main issues and risk challenges
One is that the total number of accidents in the mechanical industry remains high. In 2025, the total number of industrial safety accidents in the mechanical sector was the highest in the industrial and trade sector, accounting for 28. 1 per cent of all industrial accidents. Compared to 2024, the number of accidents and deaths has remained almost the same, with accidents reducing access to the platform and further increasing control difficulties. In 2025, there were three high-temperature melting metal spatters and six dust explosions, which could easily escalate into larger or more severe accidents. On 8 march 2025, a dust explosion occurred in huagawa mechanical processing co. Ltd., qin emperor island, hebei province, injuring 20 people, compared with 58 operators on the same day。
Second, the equipment is insufficiently protected by its nature. In 2025, mechanical injuries accounted for 36. 1 per cent of the total number of accidents and deaths in the mechanical industry and 35. 4 per cent of the total, the most frequent type of accident. Of these, accidents caused by inadequate equipment safety protection accounted for 71. 4 per cent of mechanical injuries and 72. 1 per cent of deaths. Problems such as the old and old production equipment in the mechanical industry, poor safety quality, inadequate levels of safety protection, lack of security early warning functions and low levels of physical safety are prevalent. In addition to the problems highlighted, problems such as inappropriate operation of the unit of use, inadequate safety awareness and skills of practitioners, failure of safety devices or failure to detect hazards in a timely manner are highly likely to trigger accidents。
Thirdly, there is a high risk of accidents in inspection and maintenance operations. In 2025, the mechanical industry accounted for 21. 0 per cent of accidents and 20. 7 per cent of deaths in the mechanical industry, with the largest number of accidents and deaths in the mechanical industry among the 13 primary production processes. Mechanical injuries, high-level crashes and physical attacks are the main types of accidents in inspection and repair operations, accounting for 75. 4 per cent of the number of accidents and deaths in inspection and maintenance operations and 75. 4 per cent of deaths. The lack of analysis of hazardous and harmful factors in inspection and maintenance operations, the lack of complete energy isolation and energy release, and inadequate safety protection, combined with special operational risks, such as heights, fire and limited space, has led to a higher risk of accidents in inspection and maintenance operations。
Fourth, security controls were not in place for outsourced operations. Compared to 2024, the number of accidents and deaths in the outsourced units of the mechanical industry increased by 93. 8 per cent and 113. 3 per cent, respectively. The issuer's review of the qualifications of the contractor, the control of the course of operations and the lack of implementation of the main responsibility, including the issuer's review of the contractor's qualifications, the control of the course of the operation, the education and training, and the problems of “package without care” and sub-contracting in violation of the law were highlighted. The high efficiency of the contractor, the high mobility of its staff and the blind compression of its working hours have led to a lack of risk identification and control, the occurrence of “triple violations” and the high operational risks and the complexity of the environment, which make it highly vulnerable to accidents。
Fifthly, new risk incident prevention and control face greater challenges. New equipment applications for new processes, such as lithium ion batteries, enrichment production (3d printing), automated mechanical arms and automated stereo warehouses, have accelerated, posing new risks. Existing management models, technical tools and safety controls are not matched, safety standards for equipment for new technologies in the mechanical industry lag behind industry development, while some mechanical enterprises are less aware of the working mechanisms for the safety of equipment for new technologies, inadequate safety practices and inadequate protection and control measures, resulting in a lack of new risk-control capabilities. A typical case was the dust flash incident that occurred on 13 march 2025 when guangdong precious smart technologies ltd. Cleared the core of 3d printing equipment, resulting in three injuries。
Iii. Next steps
The first is to focus on critical security risks and to deepen the dynamics of major accidents. Focusing on high-risk areas such as high-temperature melted metals, dust blasts, limited space and hazardous chemicals, focusing on the dynamics of major accident hazards is zero, and promoting incentives for businesses to self-register and internal reporting of common hazards. Strengthening of casting melting furnaces and watering of operational sites, massive accumulation of explosive dust, leakage of gas equipment and hazardous chemical irregularities. Promote automated trans-shipment for high-temperature melted metal enterprises and use automated polishing and wet dust removal processes to reduce accident risk。
The second is to increase the level of physical safety of equipment facilities and to make every effort to reduce the overall number of accidents. Expedite the upgrading of the security technology at old equipment facilities, increase the level of equipment security protection, ensure that protective measures are in place for equipment exposed to rotational areas, automation equipment operational areas, sound alarms, perimeter fencing, etc., and ensure the effective operation of security facilities such as travel limits, emergency parking, lock-outs, etc. The operational procedures are regulated, and temporary disposal of production anomalies must be preceded by power cuts and trigger safety devices. Efforts have been made to reduce the high incidence of accidents, such as mechanical injuries, object strikes and electrocution, and to effectively reduce the total number of accidents。
Third is the strengthening of maintenance practices to effectively control and control accident risk. (c) to urge enterprises to exercise strict control over the exchange of safety techniques and risk identification for maintenance operations, to regulate the handling of special operating tickets, to strictly enforce the power cut-off, lock-up and billing system, and to ensure that equipment and safety facilities are completed before they can operate. The full-time supervision of persons is strictly prohibited, with no special tools, and in case of lack of conditions, the equipment and cleaning operations are strictly prohibited. Strict pre-pilot security checks to confirm the full evacuation of personnel in the area of operations before the lock can be lifted. Operators must be specially trained and qualified to properly wear labour safety supplies, and temporary disposal equipment anomalies must trigger such devices as stoppage, raster protection, etc., so as to avoid security risks such as mishandling and misstarting from the whole process。
Fourth is the effective control of outsourcing operations and the containment of the increasing momentum of outsourcing incidents. In response to the risk characteristics of fragmented outsourcing operations in the mechanical industry and the small size of the contractor unit, the main responsibility of the awarding unit is strictly enforced, the outsourcing team's access, operations, exit from full-process closed-ring management is enhanced, and the rebound momentum of outsourced operations is effectively controlled. Strict review of the qualifications of the outsourced units, security management capabilities and certified induction of operational staff. Targeted safety techniques are being developed to identify mechanical operational risk points, safety protocols and emergency response measures, and on-site safety protection and custody measures are being implemented. Arrange dedicated personnel to oversee outsourced operations, strictly control irregular operations and over-scope operations, and ensure that outsourced personnel properly wear lau supplies. Regular security training and appraisal of outsourced personnel, establishment of security desk accounts, security assessments and feedback on experience after high-risk operations have been completed, and closed-cycle management of the entire process。
The fifth is technology-enabled mechanical safety and increased risk preparedness. In line with the ministry's priority laboratories such as dust protection, industrial and trade safety regulations, and the priority science and technology project, research is being carried out on new industrial risks, exploring the use of technology such as artificial intelligence plus for mechanical safety, to improve risk management and risk screening and management. In high-risk locations such as lithium battery assembly, casting operations and 3d printing, the use of hazard intelligence detection and identification techniques is explored to improve on-site security control effectiveness. Research has been undertaken to develop safety norms for new energy vehicle manufacturing, 3d printing, etc., and to focus on the risk of accidents in emerging areas。
