Electrical Safe Work Practices for Small Manufacturing Shops

Arc flashes are not just a utility problem. They happen in food plants, machine shops, and packaging facilities where maintenance teams troubleshoot live panels to “save time.” OSHA 1910.333 and 1910.335 require you to work de-energized unless you can prove it’s infeasible or creates a greater hazard. NFPA 70E explains how, yet many smaller companies still rely on tribal knowledge and worn lockout kits. Here’s how to modernize your program without hiring an entire electrical engineering department.

Start With an Accurate Electrical One-Line

You cannot manage what you cannot see. Update your single-line diagrams so they reflect reality—every disconnect, transformer, panel, and large motor. Label each component in the field to match the drawing. When contractors arrive, they can orient themselves quickly, and when you plan lockouts you know exactly which sources feed the equipment. Worksafely SMB users upload diagrams directly into asset records so technicians always have the latest version.

Perform an Arc-Flash Risk Assessment

Hire a qualified electrical engineer or firm to conduct an arc-flash study. They will calculate incident energy, determine protective boundaries, and recommend PPE categories. Once complete, apply durable labels to each panel showing available fault current, working distance, required PPE, and approach boundaries. Update the study at least every five years or whenever you add major equipment, change the utility feed, or reconfigure distribution.

Enforce the "De-Energize First" Rule

Lockout/tagout and electrical safety go hand in hand. Require technicians to open disconnects, apply locks, test for absence of voltage with a properly rated meter, and install grounds if there’s stored energy. Energized work should be the rare exception. When it truly is necessary—diagnostics that cannot be performed de-energized—issue an energized work permit that documents the task, shock/arc risk, PPE, and supervisor approval. Keep those permits on file to prove you followed NFPA 70E Article 130.

Issue the Right PPE and Tools

Arc-rated clothing, voltage-rated gloves, face shields, balaclavas, and hearing protection must match the hazard level on your labels. Inspect gloves every use, send them for testing every six months, and store them properly. Provide insulated tools that meet ASTM F1505, non-contact voltage detectors, and meter-proofing devices. Train technicians to verify their meters on a known source before and after testing so they never rely on a dead meter.

Maintain Electrical Equipment

Dust, moisture, and loose connections drive most arc-flash events. Schedule infrared scans, torque checks, and cleaning for switchgear, MCCs, and panelboards. Replace worn breakers and contactors before they fail. Document every maintenance activity, including contractor work, so you can prove compliance with NFPA 70B’s maintenance expectations. A well-maintained system lowers incident energy by keeping overcurrent devices operating as designed.

Train Everyone Who Might Open a Panel

Qualified person training needs to go beyond “don’t touch.” Cover shock approach boundaries, arc-flash boundaries, PPE selection, meter use, and the energized work permit process. Include supervisors so they understand why jobs take longer when done safely. Refresh training at least every three years or when standards change. For unqualified employees, focus on hazard awareness: stay out of electrical rooms, respect boundaries, and report missing covers immediately.

Integrate Electrical Safety Into Daily Operations

Add electrical checks to pre-start inspections, include arc-flash reminders in toolbox talks, and audit lockout/tagout procedures with electrical tasks in mind. When you purchase new equipment, require suppliers to provide updated one-lines, recommended breaker sizes, and maintenance instructions. The more you treat electrical safety as part of normal operations, the less likely employees are to take dangerous shortcuts.

Next step: Store your one-lines, arc-flash labels, and energized work permits in Worksafely SMB so technicians, contractors, and auditors all see the same controlled documents.