The use of collaborative robots, or cobots, is rising fast in factories, warehouses, and labs. These machines are designed to work safely with humans, but that doesn’t mean they’re risk-free. Understanding the real safety stats can help companies plan better, train smarter, and avoid accidents. This article walks through 30 key safety stats—each followed by clear insights and practical steps you can take.
1. 90% of collaborative robot (cobot) incidents occur during programming or maintenance.
Programming and maintenance are the most hands-on stages in the lifecycle of a cobot. During these times, human workers are in close contact with robotic arms, tools, and moving parts.
Unlike during regular operations, safety features might be temporarily disabled or overridden to test the robot. That’s when risk is highest.
To prevent accidents, always isolate power when making updates or doing repairs. If live testing is necessary, make sure only trained staff are present, and safety zones are marked clearly.
Use pendant controls that include emergency stop buttons. Any programming interface should display clear warnings when a cobot is active.
Train your team to use shadow mode or slow speed settings when teaching movements. Limit the use of manual overrides and always verify routines before full-speed operation. The goal is to control both the robot’s actions and the environment.
2. 43% of cobot-related injuries are caused by unexpected robot motion.
Cobots can sometimes move in ways that users don’t expect. This includes jerky arm movements, sudden changes in direction, or restarts after a brief pause. Such behavior can surprise even experienced operators and lead to injuries, especially if limbs or hands are in the path.
To reduce surprise movements, program soft start/stop motions. Avoid unnecessary speed fluctuations.
Incorporate safety-rated software that monitors intent and detects irregular commands. Use movement prediction tools that simulate an action before it’s carried out.
Teach users to treat every cobot as “live” unless clearly powered down. Even after a pause, the robot could resume action if it’s not fully stopped. Set up audible alerts or light signals to notify nearby workers before any movement begins.
The more predictable the robot, the safer the environment becomes.
3. 70% of manufacturers reported cobot safety as their top concern when adopting automation.
When adding cobots to the workplace, most businesses are not worried about cost or speed—they’re thinking about safety first.
This makes sense. If something goes wrong, it’s not just about injuries. There’s downtime, legal exposure, and reputation on the line.
If you’re considering cobots, start with a full safety risk assessment. Map out every interaction between the machine and humans. Consider both normal tasks and edge cases—like restarts, cleaning, or jams.
Ask your vendor to provide full safety documentation, including compliance with ISO/TS 15066.
You should also bring your safety officer or EHS team into early discussions. Safety isn’t a “later” thing. Build safety into the design, not after installation. And make sure your ROI includes the cost of training, fencing, sensors, and downtime.
4. 86% of cobot incidents involve human error rather than mechanical failure.
It’s easy to blame machines, but in most cases, it’s the human decisions that lead to accidents. Whether it’s bypassing a safety interlock, rushing a task, or just being distracted—these are the small mistakes that can cause serious harm.
That means prevention must focus on people, not just machines. Train your workers deeply on how cobots behave and what their limits are. Make safety part of your daily routine, not just an annual course.
Also, build a culture where workers feel comfortable speaking up. If something feels off, they should be able to pause work without fear of punishment. Empower them to own safety.
Put up visual cues around the workspace to remind people about safe practices. It may seem small, but consistent reminders lead to long-term behavior change.
5. 60% of cobot safety breaches occur due to inadequate risk assessment.
If you don’t know where the risks are, you can’t prevent them. Skipping or rushing a risk assessment is like walking into a dark room with sharp objects—you might be lucky, but eventually, something will go wrong.
Make your assessment thorough. Look at every stage: startup, normal operation, maintenance, emergency stops, and even shutdowns. Don’t just list the risks—assign a likelihood and impact score to each. Then document what you’ll do to control or eliminate them.
Invite a diverse team to review the workspace: engineers, floor workers, safety managers, and even HR. Everyone sees risks differently, and that’s a good thing. After installation, review your risk log every six months or whenever you change tasks or layout.
6. 30% of workplace robot injuries happen in facilities lacking proper safety training.
Training isn’t a checkbox—it’s a frontline defense. When workers don’t fully understand how to work with cobots, they make assumptions. They guess where it’s safe to stand or how close they can get. That’s where injuries happen.
Build a training program that’s practical, not theoretical. Use real robots, real scenarios, and real risks. Include video walkthroughs, hands-on sessions, and a written guide. Make sure every operator, technician, and supervisor is trained—no exceptions.
Also, don’t stop at one session. Refreshers every 6–12 months help keep knowledge sharp. And if an incident happens, hold a short safety stand-down the next day to go over lessons learned. The best programs are the ones that evolve with experience.
7. Cobots have a 70% lower injury rate compared to traditional industrial robots.
This stat gives us good news. Cobots are designed to be safer by default. They have built-in sensors, lower speeds, and force-limiting features that industrial robots don’t. But that doesn’t mean you can be careless.
Keep in mind that “safer” is not “safe.” You still need protocols, training, and inspections. Use the cobot’s software to set speed limits, define virtual zones, and track movement logs. Take advantage of safety analytics if available.
Also, remember that the cobot’s surrounding environment affects safety. Even a gentle cobot can be risky if it handles sharp tools or interacts with heavy parts. Treat the whole system—not just the robot—as your safety unit.
8. 95% of cobot deployments involve some form of integrated safety sensor.
Most cobots come with built-in sensors like torque sensors, cameras, and proximity detectors. These tools help the robot detect when something—or someone—is nearby and adjust its actions accordingly.
To get the most from these sensors, calibrate them properly during setup and recheck them regularly. Use the data to create safety zones and slow-down areas. For example, when a person steps into a shared zone, the robot should reduce its speed or pause entirely.
Don’t rely on default settings. Customize sensor responses to match your actual tasks. And document how the sensors respond in different scenarios so that everyone on your team understands what to expect. A robot that reacts in real-time keeps everyone safer.
9. 50% of cobot incidents could be prevented with proper safety fencing or barriers.
Even though cobots are designed to work without cages, that doesn’t mean barriers are useless. A simple fence or marked zone can stop people from accidentally stepping into a robot’s work area at the wrong time.
Think about adding flexible barriers, like light curtains or safety mats. These can stop the robot if someone crosses into a defined zone. You can also use visual floor markings to show where it’s safe to walk or stand.
Make sure your team respects the barriers. Don’t allow shortcuts or let people lean over fences to “just grab something.” Keep the area around the cobot clear of clutter so visibility and access are never compromised.
10. 80% of cobot-related incidents occur within the first year of deployment.
The first year is when workers are still getting used to the new system, and even experienced staff might make risky decisions. This is also when bugs and integration issues are most likely to show up.
To reduce early-stage risk, roll out your cobot in phases. Start with a pilot project, test it with a small team, and document every incident—no matter how minor. Then revise your procedures based on what you learn before full-scale deployment.
Hold weekly check-ins during the first three months. Make it easy for workers to report near-misses. The more you listen early on, the fewer surprises you’ll have later.
11. 68% of incidents happen when safety protocols are manually overridden.
When workers bypass safety features to “get the job done faster,” they open the door to danger. Whether it’s disabling a sensor or overriding a speed limit, these actions usually come from time pressure or a lack of understanding.
If this happens at your site, don’t just blame the operator. Look at the system. Are the safety protocols causing delays? Is the workflow too slow? Is the training unclear?
Fix the root cause, not just the behavior. Also, track every override action in your system logs. Set up alerts when overrides happen too often or during night shifts. Make it clear to your team that safety overrides are a last resort—not standard practice.
12. Only 12% of companies conduct regular safety audits on collaborative robots.
Audits are often skipped because they take time, but that’s a mistake. Regular checks keep your safety measures effective and help catch issues before they become problems.
Set up a simple monthly audit checklist. Include sensor calibration, software updates, emergency stop functionality, and workspace layout. Rotate audit responsibilities among team leads so it doesn’t become routine or overlooked.
Document each audit and review the findings quarterly. Use what you learn to update training, signage, and work routines. A little attention every month can save a major incident later.
13. 35% of cobot accidents are linked to poor workspace design.
A cramped, cluttered, or poorly lit area increases the chance of accidents. Workers trip over things, miss signals, or get too close to moving parts because the space doesn’t guide them properly.
Design your workspace with intention. Leave enough clearance around the cobot for people to walk safely. Use visual lines on the floor to separate robot zones from walking paths. Make sure warning signs are clearly visible and positioned at eye level.
If you rearrange your workspace, redo your risk assessment. Even small changes can create blind spots or new hazards. Design isn’t just about efficiency—it’s about guiding behavior safely.
14. 90% of safety-rated cobots comply with ISO 10218 and ISO/TS 15066 standards.
These international standards define how cobots should behave to be considered safe. They cover speed limits, force thresholds, and how to test for safe human-robot interaction.
When buying or evaluating a cobot, ask for certification proof. Make sure the manufacturer’s claims are backed by testing to these standards. If your robot isn’t compliant, you’re taking on extra liability.
If your system includes add-ons like grippers, conveyor belts, or cameras, check whether those components also meet safety standards. Compliance should apply to the entire workcell—not just the robot arm.
15. 78% of workers feel safer when cobots are equipped with force-limiting functions.
Force-limiting means the robot will stop or back away when it meets resistance, like touching a person. This feature alone makes a big difference in how comfortable people feel working near cobots.
Turn this function on by default, and test it regularly. Train your staff on how it works. For example, let them press gently against the robot arm during training so they understand the stop response.
Psychological safety matters too. When workers feel confident around cobots, they make fewer errors and are less anxious. It’s not just about the tech—it’s about how the tech makes people feel.
16. Force and speed monitoring prevent over 40% of potential cobot injuries.
Monitoring the force and speed of a cobot’s movements helps it stay within safe limits.
These limits are especially important when the robot shares a workspace with humans. Too much speed or pressure—even for a second—can lead to cuts, pinches, or worse.
Most cobots have built-in monitoring tools. Make sure these tools are properly configured. Define safe thresholds for different tasks. For example, a task involving small electronics may need much lower force than one involving lifting boxes.
If your robot performs variable tasks, build dynamic profiles that adjust speed and force based on what the robot is doing.
Regularly test these limits and update them as your workflows evolve. Monitoring isn’t a one-time task—it’s a living part of your safety system.
17. 85% of companies using cobots conduct initial safety risk assessments.
That’s a strong majority, and it’s a good sign. Still, the initial assessment is only the beginning. It tells you what risks might exist on day one—but those risks change over time.
Make your assessment a living document. Revisit it after layout changes, new tooling, or software updates. Bring in your workers for feedback. They see things management might miss.
Also, save versions of your risk assessments. Keeping track of changes over time can help you learn from past mistakes and defend your safety efforts if an incident occurs. Safety isn’t static, and neither is risk.
18. 55% of small to mid-sized businesses do not have formal cobot safety policies.
This is a dangerous gap. Without a written policy, teams rely on memory, guesswork, or habits. And when accidents happen, there’s no paper trail to show you tried to do the right thing.
Your policy doesn’t need to be long. Start with a simple document that explains: who’s in charge of cobot safety, how training works, what safety features are required, and what to do if something goes wrong.
Post it where everyone can see it. Review it with new hires. And most importantly, update it often. Policies that gather dust don’t protect anyone. Policies that live in your day-to-day operations do.
19. Emergency stop buttons reduce reaction time to incidents by 60%.
When something goes wrong, every second counts. A clear, easy-to-reach emergency stop can be the difference between a close call and a serious injury.
Install emergency stop buttons near every cobot and make sure they’re labeled clearly. Walk your team through how and when to use them. Don’t assume everyone knows.
Check the stops monthly. If one fails or is slow to respond, fix it immediately. During training, include hands-on use of emergency stops. Practicing under calm conditions helps workers act fast under pressure.
20. 20% of cobot accidents occur due to lack of employee training on safe interaction.
Even if the machine is safe, untrained humans can still get hurt. Training needs to go beyond button-pushing. Workers must understand how the cobot thinks, reacts, and stops.
Break training into small, focused sessions. One day on programming. One on emergency procedures. One on interaction zones. Make it hands-on. Don’t just show a video—let them touch, test, and try.
Keep records of every trained employee. Don’t allow anyone to work with or near cobots without training. And if someone switches roles or tasks, give them updated training right away.
21. 72% of companies using vision systems report fewer cobot safety violations.
Vision systems use cameras or lidar to help cobots “see” the world around them. They can spot when a person gets too close and trigger a slowdown or stop.
If your cobot supports vision, use it. Set zones that change in real time depending on where people are. Connect the vision system to your safety controller so the robot reacts instantly to movement.
Place cameras at angles that cover all blind spots. Don’t just rely on a top-down view. And test the system under different lighting conditions, including shadows or glare. A clear view means a safer workspace.
22. 64% of cobot installations utilize light curtains or area scanners for safety.
Light curtains create invisible beams that, when broken, stop the robot. Area scanners do the same with lasers, offering more flexibility in shape and distance. Both are strong tools for keeping people out of danger zones.
Set up your zones based on how people move through the space. Don’t just cover the robot—cover the areas around tables, bins, and walkways too. Give workers space to move safely without triggering constant shutdowns.
Update your scanner zones if your layout changes. And don’t forget to clean the sensors. Dust or dirt can block the beams, causing false triggers or blind spots.
23. 88% of cobot-related injuries are non-fatal and involve bruising or pinching.
That’s still a problem. Just because an injury doesn’t require a hospital visit doesn’t mean it’s okay. Even small injuries hurt morale, productivity, and confidence in automation.
Review every injury report. What caused the pinch? Was it a tool, a moving arm, or a person in the wrong spot? Use these findings to adjust your robot’s movement paths and speed limits.
Also, install padding on sharp edges, and design grippers with rounded tips. Every little detail helps avoid injuries. Your goal is not just to avoid fatalities—but to eliminate injuries of all sizes.
24. 40% of safety incidents occur during cobot-human shared workspace tasks.
Cobots are meant to work side-by-side with people—but that’s also when things get tricky. The more time humans and machines spend in the same space, the more chances for confusion or collisions.
Use “coexistence zones” where the robot slows down automatically when people are near. Assign specific areas or timing windows for human access. For example, allow humans to load parts while the robot is paused.
Don’t rely on people’s judgment alone. Make safety a system, not a suggestion. Use signs, lights, and movement indicators to help workers understand what the robot is about to do.
25. Cobots reduce repetitive strain injuries by up to 45%.
One of the biggest advantages of cobots is their ability to handle repetitive, awkward, or heavy tasks that usually lead to human strain over time.
These tasks might seem small day-to-day, but they add up—leading to long-term injuries that cost both the worker and the company.
Use cobots to take over tasks like lifting, twisting, pushing, or turning that put stress on joints and muscles. Even reducing the number of repetitions per worker can make a huge difference.
If your team stacks items all day, for instance, having a cobot do the lifting while the human focuses on quality checks is a great way to divide the work safely.
Make sure you choose the right end-effector and movement path so the cobot handles the task gently but effectively. Review ergonomics regularly and ask your workers where they feel pain or fatigue. Let their feedback guide your automation efforts.
26. 50% of manufacturers conduct re-assessments after layout or task changes.
Half of companies take action when they change their layout—and the other half take a risk. Anytime you move a workstation, add a new table, or switch tasks, the risk profile changes.
Don’t wait for an accident to happen. Reassess your cobot setup after any significant change. Look at movement paths, human traffic, lighting, new tool attachments, and reach zones. Just because the cobot is doing the same task doesn’t mean the space around it is equally safe.
Get the safety team involved early in the planning stage. If you plan to make a change next week, do your assessment now—not after installation. Proactive reviews prevent reactive mistakes.
27. Collaborative robots account for less than 5% of total robot-related injuries.
This statistic shows that cobots are generally safer than their industrial counterparts. But it’s also easy to become overconfident with such a low percentage. Low doesn’t mean zero.
Even a single injury from a cobot can damage morale and lead to costly downtime or legal issues. So treat every near-miss seriously. Log it, analyze it, and fix it.
Make sure every incident—no matter how small—goes into a tracking system. Over time, this data tells you where improvements are needed. Use it to adjust your procedures and keep your cobot program on the safe side of that 5%.
28. 92% of companies using cobots report improved worker satisfaction with safety.
People like feeling safe at work. When cobots are used properly—with clear guidelines and reliable safety systems—workers trust the environment more. That trust leads to better focus, fewer mistakes, and more job satisfaction.
Let your team be part of the safety process. Ask for feedback on how the cobot moves, how it signals, and how easy it is to stop. Use their suggestions to make improvements.
When people see their feedback turn into real changes, they engage more. That engagement leads to stronger safety habits and a better workplace culture. Safety isn’t just about avoiding harm—it’s about building confidence and trust.
29. 77% of incidents are associated with improperly integrated safety systems.
If the safety parts don’t talk to each other—or worse, they interfere with each other—you’re asking for trouble. Integration issues include sensors not triggering properly, emergency stops not halting the entire system, or zones being mismatched.
Always treat your cobot and its peripherals as one system. That includes conveyors, part feeders, cameras, grippers, and software. Test how everything behaves under stress. Simulate an emergency and make sure every part responds instantly and as expected.
Work with integrators who know both robotics and safety. Double-check that all components are certified and compliant. And before going live, perform a full validation under real working conditions.
30. 84% of cobot accidents are preventable with comprehensive safety training.
This final stat says it all. Most cobot-related accidents don’t come from faulty hardware—they come from people not knowing what to do. And that’s good news, because training is something you can control.
Start with a strong onboarding program for all new employees. Include robot basics, safety features, and emergency protocols. Then provide task-specific training based on what each person does. Don’t stop there—follow up regularly, especially when something changes.
Make your training engaging. Use real-life examples. Ask employees to explain safety steps in their own words. This helps you see who truly understands and who needs more help.
Reinforce safety culture every day. A poster, a 2-minute safety talk, or a walk-through from a supervisor—these little touches add up. In the long run, the best way to protect your people is to empower them with knowledge.
wrapping it up
Collaborative robots can make the workplace safer, more efficient, and less physically demanding—but only if you treat safety as a top priority from day one.
These 30 stats aren’t just numbers; they’re lessons from the field. Behind each one is a real risk—and a real opportunity to do better.
