Sector summary

This sector comprises establishments primarily engaged in the manufacturing of motor vehicles, including establishments that manufacture only motor vehicle chassis (including truck cabs), such as motor vehicle, truck body and trailer and automotive parts manufacturers.

Key hazards

The following list represents hazards to which workers are commonly exposed in the automotive sector:

  • activities that may lead to musculoskeletal disorders (MSD)
  • machine (and powered equipment) hazards such as improper lock-out and unguarded equipment
  • material handling hazards (such as workers being struck by objects, caught or crushed between objects)
  • slips, trips and falls
  • exposures (such as chemicals, fumes and environmental conditions)
  • noise
  • transportation equipment and vehicle traffic
  • fire and explosion
  • confined spaces.

In general, hazards that are not covered by a regulation and hazards in workplaces not covered by a sector-specific regulation are addressed through the application of the general duty clause 25(2)(h) of the Occupational health and safety Act (OHSA).

Workplace parties should refer to the narrative portion of the field visit report, if they have received one, for further information, or contact their health and safety association for guidance.

In addition to any other hazards which may be present in a workplace, all employers covered by the OHSA must comply with the requirements for workplace violence and harassment. The act sets out requirements for workplace violence and harassment in sections 32.0.1 to 32.0.8. Further information regarding the requirements related to workplace violence can be found in the Ministry of Labour guide Workplace violence and harassment: Understanding the law.

Additional information, including more information about new workplace harassment provisions, can be found on the MOL topic webpages for Workplace Violence and Workplace Harassment. Employers may wish to consider the use of the ministry’s Code of Practice to Address Workplace Harassment under the OHSA.

Musculoskeletal disorders (MSDs)

Workplace pains and strains can be serious and disabling for workers, causing pain and suffering ranging from discomfort to severe disability.

MSD is not a medical diagnosis; it is an umbrella term for a group of injuries. Some of these injuries include: back pain (low back strain, etc.), muscle strain, tendonitis, carpal tunnel syndrome (CTS), rotator cuff syndrome, tennis elbow and shoulder pain.

  • Identify and assess job-related MSD risk factors (i.e. identify tasks and activities involving manual material handling, use of ladders, static or repetitive movements etc.)
  • Review training on job-specific MSD risk factors.
  • Assess controls to reduce worker exposure to MSD.
  • Contact your health and safety association for guidance in assessments and prevention of MSD.

Machine hazards

A Pre-start health and safety review may be required (as per section 7 of Regulation 851) if new equipment (or modifications to equipment) are installed that interface with certain electrical safeguarding devices. Please see the section Pre-start health and safety review found later in this document for more information.

Machine or transmission start-up (improper lockout)

Injuries experienced by accidental machine start-up can include lacerations, crushing and amputations. In some circumstances these injuries can cause permanent disability or death.

The Regulation for Industrial Establishments (Regulation 851), applies to industrial establishments (such as an office building, factory, arena, shop or office or any land, buildings and structures pertaining thereto) and sets out requirements for worker protection against machine start-up in sections 75 and 76.

  • Review repair/maintenance of machinery [section 75].
  • Ensure requirement/compliance with lockout procedures [sections 75 and 76].
  •  Ensure that instruction and information is provided to a worker on the hazard and the requirements to isolate and lockout hazardous energy [OHSA clauses 25(2)(a) and 25(2)(d)].

Unguarded equipment

Injuries to workers can include lacerations, amputations, crush by entanglement and loss of consciousness. Serious injuries can lead to permanent disability or death.

Hazards due to unguarded equipment include worker exposure to pinch points, moving (rotating) equipment, and in-running nip hazards. Equipment that has exposed moving parts such as cutting operations, conveyors, augers, equipment using power take-off (PTO) and exposed drive-motor assemblies used to power compressors and, or ventilation fans will endanger a worker. Regulation 851 sets out requirements for guarding of equipment in sections 24, 25, 26, 28, 31 and 32.

  • Ensure that the requirements for the guarding of prime movers, or transmission equipment are followed [section 24].
  • Ensure that pinch points are guarded [section 25].

Material handling hazards: struck by objects, caught between or crushed by objects

Injuries associated with material handling can include workers being struck by objects, caught between objects and/or crushed by mechanical compression. Manual material handling may also lead to MSD.

Regulation 851 sets out requirements for material handling in sections, 45, 46, 47, 48, 49 and 50. Section 51 contains requirements regarding mechanical lifting devices.

  • Review operations/processes involving the movement of raw material and product from receiving area to production line and from production line to shipping area.
  • Review operations/processes involving assembly line or similar style of raw material or product movement [section 45].
  • Ensure safe warehousing/storage operations [clause 45(b)].
  • Ensure that mechanical lifting devices are maintained in good condition, are operated by a competent person and are capable of handling loads [section 51].

Slips, trips and falls

Slips, trips and falls hazards include hazards that result in workers falling onto the same surface or falling from a height.

Injuries to workers can include fractures, lacerations and loss of consciousness. In extreme circumstances injuries caused from a fall can lead to permanent disability or death.

The Regulation for Industrial Establishments (Regulation 851) sets out a number of requirements for worker protection against slips, trips and falls, including but not limited to sections 11, 13, 14, 16, 73 and 85.

  • Floors and other surfaces used by workers must be free of obstructions, hazards, accumulations of ice and snow and not have a slippery surface [section 11].
  • Review requirements for guardrails to protect from falls [section 13 and 14].
  • Review fall protection equipment required when working from heights [section 85].
  • Ensure that training is provided to a worker on the use of protective clothing and equipment (i.e. fall arrest equipment) [section 79].
  • In areas requiring ladder use, review compliance with section 73.
  • Employers must provide information, instruction and supervision to protect workers from slips, trips and falls and acquaint workers with the hazards [OHSA clauses 25(2)(a) and 25(2)(d)].

Exposures

Chemical exposures

Chemicals can present hazards to workers by a variety of different mechanisms such as causing chemical burns to skin, irritation to eyes and airways and by absorption or ingestion into the body.

  • Review the use of chemicals used in the workplace such as common acids. (hydrochloric acid, sulfuric acid, nitric acid, chromic acid, acetic acid and hydrofluoric acid), common bases (ammonium hydroxide, potassium hydroxide (caustic potash) and sodium hydroxide (caustic soda), and any other chemicals used.
  • Ensure compliance with requirement for skin protection [Regulation 851, section 84].
  • Ensure compliance with requirement for eye protection [section 81].
  • Ensure compliance with requirement for emergency eyewash facilities [section 124].
  • Ensure compliance with requirement for emergency shower facilities [section 125].
  • Ensure that workers are trained about precautions to take, use of protective equipment and emergency procedures [section130].
  • Ensure that the requirements outlined in the Workplace Hazardous Materials Information System (WHMIS) (Regulation 860) and the requirements to monitor and control exposure limits as identified in the Control of Exposure to Biological or Chemical Agents (Regulation 833) are followed.

General workplace environment

Workplace hazards related to the general workplace environment may include exposure to fumes and other contaminants related to poor or inadequate ventilation. Exposure to cold or heat may also be a hazard to worker health and safety.

  • Ensure workplace ventilation is adequate [Regulation 851, sections 127 and 128].
  • Ensure that a workplace is adequately heated where appropriate [section 129].
  • Review sources of heat or excessive temperatures in the workplace and ensure that adequate controls are in place to protect workers.

Noise

Injuries to workers can include varying degrees of noise-induced hearing loss.

The Noise Regulation O. Reg. 381/15 sets out workplace requirements regarding noise.

  • Review the engineering controls and administrative (work practices) controls in place to reduce noise levels and exposures (mufflers on air exhausts, mechanical damping, vibration isolators, enclosures, and limiting worker’s exposure time).
  • Review the availability and use of hearing protection [subsection 2(6)].
  • Review the type of hearing protection provided [subsection 4(1)].
  • Review placement of warning signs at approaches to noisy areas [subsection 2(7)].
  • Review the training provided to workers [section 3].
  • Personal protective equipment is to be used only as a last resort. Engineering controls and work practices must be used where practicable [subsection 2(5)].

Transportation equipment and vehicle traffic

Injuries can occur when workers are struck by or come into contact with motorized equipment or vehicles in a workplace.

Where vehicles or motorized equipment are present:

  • review locations where pedestrians and vehicles may be present in a workplace.
  • ensure that controls are in place to adequately protect workers from vehicles and motorized equipment [Regulation 851, section 20].

A comprehensive program to protect workers may include an assessment of the risks and implementation of measures and procedures appropriate in the circumstances, such as warning lights, signs, signallers, barriers and worker training. The use of reflective clothing appropriate for the circumstances is also important. Workplace parties may wish to refer to the Canadian Standards Association’s standard CSA Z96-15 which contains performance criteria for high visibility garments. CSA Standard Z96-15 - High-visibility safety apparel is available through the Canadian Standards Association (CSA).

Fire and Explosion

Flammable liquids

Injuries from fire and, or explosion can include burns, lacerations, fractures, and loss of consciousness. Serious injuries can lead to permanent disability or death.

  • Ensure the safe use of solvents in the workplace such as acetone and toluene.
  • Review requirements for flammable liquids such as the requirements for:
    • grounding and bonding [clause 22(4)(b)]
    • proper storage of flammable liquids [section 22]
    • ventilation and work area protection [sections 22 and 63].
  • Review the requirements outlined in the WHMIS/Regulation 860 and the requirements to monitor and control exposure limits as identified in Regulation 833.

Fire and explosion: dust collectors

Industrial dust collectors, hoppers and bins can contain combustible dusts, including metal shavings.

Regulation 851 sets out requirements for dust collectors in sections 63, 64 and 65.

Confined space

A confined space means a fully or partially enclosed space that is not both designed and constructed for continuous human occupancy, and in which atmospheric hazards may occur because of its construction, location or contents or because of work that is done in it.

Injuries to workers can include loss of consciousness and collateral injuries sustained as a result of loss of consciousness.

In some circumstances such as oxygen depletion, toxic substance inhalation or explosive atmosphere, injuries to workers can lead to permanent disability or death.

The Regulation for Confined Spaces (O. Reg. 632/05) sets out workplace requirements regarding confined spaces.

  • Review work locations that meet the definition of confined space.
  • Ensure compliance with the requirement to have a program in place for confined spaces [section 5].
  • Ensure compliance with the requirement to have adequate assessments of confined spaces carried out [section 6].
  • Ensure compliance with requirement to have an adequate plan developed and implemented for confined space entry [section 7].
  • Review compliance with requirement for worker training [section 9].

Trends

Table 1: Fatalities and critical injuries in automotive sector by fiscal year
Events2012-132013-142014-152015-162016-17
Fatalities00210
Critical injuries3535343145
  • Only critical injury events reported to the ministry are included here.
  • These represent data that were reported to the ministry and may not represent what actually occurred at the workplace.
  • The critical injury numbers represent critical injuries reported to the ministry and not necessarily critical injuries as defined by the Occupational health and safety Act.
  • Non-workers who are critically injured may also be included in the ministry’s data.
  • The Ministry of Labour tracks and reports fatalities at workplaces covered by the OHSA. This excludes death from natural causes, death of non-workers at a workplace, suicides, death as a result of a criminal act or traffic accident (unless the OHSA is also implicated) and death from occupational exposures that occurred many years ago.
  • Data are subject to change because of inspectors’ updates to the database.
Table 2: Events and activities in automotive by fiscal year
Events and activities2012-132013-142014-152015-162016-17
Field visits1,1651,4611,2681,5681441
Orders1,7822,1532,4042,6182,065
Complaints1513311399429
Work refusals151391010

Most common orders issued under the OHSA

From April 1, 2016, to March 31, 2017, the most common orders issued by the Ministry of Labour under the OHSA were:

  • An employer shall ensure that, the equipment, materials and protective devices provided by the employer are maintained in good condition [clause 25(1)(b)].
  • An employer shall, take every precaution reasonable in the circumstances for the protection of a worker [clause 25(2)(h)].
  • An employer shall provide information, instruction and supervision to a worker to protect the health or safety of the worker [clause 25(2)(a)].
  • An employer shall post in the workplace a copy of this act and any explanatory material prepared by the ministry, both in English and the majority language of the workplace, outlining the rights, responsibilities and duties of workers [clause 25(2)(i)].
  • Orders issued to an employer related to workplace violence and harassment provisions [sections 32.0.1 through 32.0.8].

Most common orders issued under the Industrial Establishments Regulation

From April 1, 2016, to March 31, 2017, the most common orders issued by the Ministry of Labour under Regulation 851 were:

  • A lifting device shall, be thoroughly examined by a competent person to determine its capability of handling the maximum load as rated, prior to being used for the first time, and thereafter as often as necessary but not less frequently than recommended by the manufacturer and in any case, at least once a year, and a permanent record shall be kept, signed by the competent person doing the examination [clause 51(1)(b)].
  • Where a machine or prime mover or transmission equipment has an exposed moving part that may endanger the safety of any worker, the machine or prime mover or transmission equipment shall be equipped with and guarded by a guard or other device that prevents access to the moving part [section 24].
  • Where a worker is exposed to a potential hazard of injury to the eye due to contact with a biological or chemical substance, an eyewash fountain shall be provided [section 124].
  • A floor or other surface used by any worker shall be kept free of obstructions, hazards, and accumulations of refuse, snow or ice; and not have any finish or protective material used on it that is likely to make the surface slippery [section 11].
  • An in-running nip hazard or any part of a machine, device or thing that may endanger the safety of any worker shall be equipped with and guarded by a guard or other device that prevents access to the pinch point [section 25].

Applicable sections of the Regulation for Industrial Establishments

Where theRegulation for Industrial Establishments apply, some of the sections of the regulation which inspectors may use to issue orders (as appropriate) are:

  • Section 7 – pre-start health and safety review
  • Section 11 – safe work surfaces
  • Sections 13 and 14 – guardrails
  • Sections 22 and 23 – flammable liquids
  • Sections 24, 25, 26, 28 and 32 – guarding of equipment
  • Section 34 – conveyor guarding
  • Section 45 – material handling and storage
  • Section 49 – compressed gas cylinders
  • Clause 51(1)(a) – examination of lifting device
  • Clause 51(1)(b) – maximum rated load plainly marked on lifting device
  • Section 73 – portable ladder
  • Section 76 – machine lockout
  • Section 79 – personal protective equipment instruction
  • Section 81 – eye protection
  • Section 82 – foot protection
  • Section 124 – eyewash
  • Section 125 – deluge shower

Pre-start health and safety review

A pre-start review (PSR) may be required by section 7 of Regulation 851. Section 7 applies to a factory as defined by the OHSA and is intended to ensure that hazards are removed or controlled before an apparatus or process is started up. If required, the PSR must be completed before the complete installation (in-service and operating) of any apparatus, structure, or protective element.

Information about pre-start reviews can be found in the Ministry of Labour Guidelines for Pre-Start Health and Safety Reviews: How to Apply Section 7 of the Industrial Establishments Regulation.

For further information contact your health and safety association or the Professional Engineers of Ontario (PEO) for guidance in conducting a PSR or contact a professional engineer or engineering company that performs PSRs.

Applicable Regulations

Construction Regulation

Employers should be aware that in situations where construction work is undertaken, the Construction Projects Regulation (O. Reg, 213/91) may apply.

Construction work can be described as new work, additions, alterations or maintenance and repairs. The OHSA defines construction as including erection, alteration, repair, dismantling, demolition, structural maintenance, painting, land clearing, earth moving, grading, excavating, trenching, digging, boring, drilling, blasting, or concreting, the installation of any machinery or plant, and any work or undertaking in connection with a project but does not include any work or undertaking underground in a mine.

General Resources

Publications | Ministry of Labour

For information and guides, fact sheets, information bulletins, guidelines, alerts, engineering data sheets, extracts, reports, consultations, codes and standards.

Videos and photos | Ministry of Labour

To view Ministry of Labour videos and photos.

Health and safety partners

To learn about sector-assigned health and safety associations.

By the numbers: WSIB statistical report

To review Workplace safety and insurance board (WSIB) injury experience data.