Whether tripping hazards, damaged hand tools, or unreliable cable management – many safety risks in production arise from a lack of order and uncontrolled processes. This article explains how companies can improve occupational safety with simple technical means and the role that automatic retraction mechanisms play in this.

Human Error as the Main Cause of Workplace Accidents

When it comes to workplace safety, many people first think of machines: sharp edges, high temperatures, moving parts. But in practice, the greatest risk often does not come from technology, but from employee behavior. Studies show that up to 90% of all workplace accidents are due to human error. This includes shortcuts in work processes, ignoring safety rules, or poor organization in the workplace.

Such risks cannot be fully addressed through training and behavioral guidelines alone. Technical support is essential, especially in dynamic production environments where tasks often need to be completed under time pressure. Intelligent solutions that automatically eliminate common sources of error can make a valuable contribution.

Automating Order – Consistently Eliminating Tripping Hazards

Cables on the floor are not only an eyesore; they are among the most common causes of accidents in manufacturing. In areas with high foot traffic or limited visibility, they quickly become dangerous tripping hazards. Even if manual tidying is scheduled, it is often neglected in day-to-day operations – for example, during shift changes.

Technical systems that automatically retract cables when not in use offer a reliable solution. They maintain lasting order, relieve personnel, and reduce tripping hazards regardless of individual behavior. One example is our MTPReel, a cable reel with automatic retraction, specially developed for use with robotic control devices.

Controlling Retraction Movements – Effectively Protecting Users and Equipment

Another risk arises when using cable management systems, as the cable or the connected device can snap back uncontrollably – for example, if a control device is accidentally released. This can damage the device and potentially endanger employees.

Cable management systems with integrated retraction brakes ensure that cables and devices are retracted in a controlled manner. This reduces the risk of injury and protects the operational equipment in use.

Implementing Regulations – Without Additional Burden on the Team

Safe cable management is anchored in many operational guidelines and standards – such as in DGUV regulations or internal factory standards. However, compliance in day-to-day operations is error-prone if it relies solely on work instructions.

Technical solutions like an automated retraction system help reliably implement these requirements. They reduce dependence on routines and ensure consistent order – regardless of personnel changes or time pressure.

Conclusion: To Ensure Safety, You Need Systems, Not Appeals

Many safety risks in production can be significantly reduced with simple technical measures – especially when they directly address common human errors. Automatic cable retraction mechanisms are one example: they help prevent tripping hazards, protect devices, and ensure compliance – without additional effort for the team.

Companies that adopt such solutions are investing not only in safety but also in stable operations and a relieved workforce.