5 Arc Flash Mistakes Manufacturing Plants Can’t Afford to Make

Arc flash is one of the most dangerous — and most overlooked — electrical hazards in industrial environments. When systems are energized and maintenance or switching tasks are underway, even a minor failure can result in an explosive release of energy, leading to serious injury, equipment damage, or fatality.

Despite the known risks, many manufacturing plants continue to make preventable mistakes that compromise safety, compliance, and operations.

1. Outdated or Missing Arc Flash Labels

Labeling is one of the most visible — and auditable — aspects of arc flash compliance. If your facility still has labels that are more than five years old, they likely do not reflect current system conditions, available fault current, or updated working distances. Missing or faded labels can also trigger fines or shutdowns during inspections.

2. Skipping Arc Flash Risk Assessments

NFPA 70E requires facilities to conduct a formal arc flash risk assessment, including calculations, PPE selection, and hazard boundaries. Many plants either skip this step entirely or rely on outdated assessments that no longer reflect equipment modifications, layout changes, or increased loads.

3. Relying on Generic PPE

Providing general flame-resistant (FR) clothing is not the same as equipping workers with the correct arc-rated PPE for the task. Each job requires PPE that aligns with the calculated incident energy. Without accurate assessments, plants can’t provide proper gear — leaving personnel exposed during live work.

4. Inadequate Worker Training

Even with the right PPE and labeling, arc flash protection fails without proper training. Qualified electrical workers must understand hazard boundaries, PPE use, energized work permits, and incident response. Annual or biannual refresher training is critical — and often overlooked.

5. Treating Compliance as a One-Time Task

Arc flash compliance is not “set it and forget it.” Equipment degrades, system configurations evolve, and standards like NFPA 70E continue to change. Facilities that view compliance as a one-time study or labeling job are exposed — legally, financially, and operationally.

To keep your team safe and your site compliant, arc flash programs must be actively maintained and reassessed every five years or whenever major electrical changes are made.