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

Human error as the main cause of accidents at work

When people talk about occupational safety, many people first think of machines: sharp edges, high temperatures, moving parts. In practice, however, the greatest risk often comes not from technology, but from the behavior of employees. According to studies, up to 90% of all accidents at work are due to human error. This includes, for example, shortening work processes, ignoring safety rules or a lack of order in the workplace.

Such risks cannot be managed through training and behavioral instructions alone. Technical support is crucial, especially in dynamic production environments where tasks often have to be completed under time pressure. Intelligent solutions that automatically avoid typical sources of error can make a valuable contribution here.

Automating order – consistently eliminating trip hazards

Cables on the floor are not just a visual problem, they are one of the most frequent causes of accidents in production. Dangerous tripping hazards can quickly arise, especially in areas with high pedestrian traffic or restricted visibility. Even if manual tidying up is planned, it is often neglected in everyday life – for example during shift changes.

Technical systems that automatically roll up cables when not in use offer a reliable solution. They create permanent order, relieve the strain on personnel and reduce tripping hazards regardless of individual behavior. One example is our MTPReel, a cable reel with automatic retraction that has been specially developed for use on robot operating devices.

Control retraction movements – effectively protect users and devices

A further risk arises when using cable management systems if the cable or connected device snaps back unchecked – for example after an operating device is accidentally released. Not only can the device be damaged, but employees are also potentially at risk.

Cable management systems with an integrated retraction brake ensure that cables and devices are returned in a controlled manner. This reduces the risk of injury and protects the equipment used.

Implement regulations – without putting additional strain on the team

Safe cable routing is anchored in many company specifications and standards – for example in the DGUV regulations or internal factory standards. However, compliance with them during operation is prone to errors if they are solely dependent on work instructions. Technical solutions, such as an automated retraction system, help to reliably implement these specifications. They reduce dependency on routines and ensure consistent order – regardless of staff changes or time pressure.

Conclusion: If you want security, you need systems, not appeals

Many safety risks in production can be significantly reduced with simple technical measures – especially if they specifically address typical sources of human error. Automatic retraction mechanisms for cables are an example of this: they help to avoid tripping hazards, protect equipment and comply with regulations – without additional effort for the team.

Companies that rely on such solutions are not only investing in security, but also in stable processes and a relieved workforce.