From 2017 to 2020, an average of three people died and 11 were injured in factory accidents in India every day. To make matters worse, nearly 13 people are electrocuted every day, the most of any country in the world. Data from the Central Electricity Authority (CEA) further reveals that almost 40% of workplace fatalities are caused by electrical problems, which is a matter of serious concern.
Having said that, India’s manufacturing industry is growing rapidly and is expected to expand by 5% in 2024 and increase its share to 25% of the national economy by 2025. Employment in this sector is also on the rise, increasing by 7.5% in 2024. Even in 2022-23 alone. But as manufacturing booms, more workers are at risk. If India is to achieve its vision of becoming a global manufacturing hub, electrical safety must become a top priority.
Strengthening the security of India’s manufacturing future
Recognizing this, Polycab, India’s largest electrical wire and cable manufacturer, has partnered with CNBC-TV18 to host a series of conferences to address the urgent needs of electrical safety in India, ‘Infrastructure Safety: India’s Electrical We have launched “Empowering the future of the world.” After holding the first meeting of this pioneering initiative in December 2024 in Mumbai, Polycab held the second Infrastructure Safety Conference on January 7, 2025 in Chennai.
The discussion focused on manufacturing safety, with experts from various fields sharing valuable insights. Participants included Mr. Gopa Kumar S., President, National Federation of Electrical Safety Engineers, Mr. A. Thanapal, Assistant District Officer, Tamil Nadu Fire and Rescue Services, and Mr. R. Balakrishnan was included. The manufacturing sector was represented by Mr. Srivats Ram, Managing Director, Wheels India and Chairman, CII, Tamil Nadu, and Mr. RA Krishnakumar, COO, Chettinad Cement Corporation. They were joined by Polycab Executive Director Nikhil Jaisinghani and National Head of Industry Vertical Harish Bhardwaj.
Panelists emphasized the importance of safety standards, system audits, and reliable electrical infrastructure. The conclave also highlighted innovations such as IoT and advanced cabling solutions as driving India’s electrically safer and more sustainable manufacturing future.
Prioritize electrical safety
Electrical safety in manufacturing should be seen as a strategic priority, not just an afterthought, panelists said. While initiatives such as Make in India 2.0 and Aatmanirbhar Bharat have laid the foundation for industrial growth and progress, it is imperative that India’s manufacturing sector focuses on the critical role that electrical safety plays in this progress.
Mr. Harish Bhardwaj, Industrial Director, Polycab, highlighted the seriousness of electrical accidents in the country. He said: “The statistics are clear: Electrical accidents claim more than 5,000 lives a year, and productivity losses from disruptive power can reduce revenue by 5-10%. They’re not just numbers; they represent the human and economic costs of a lack of safety.”
However, the path to a safer and more sustainable manufacturing future requires a collective effort. This requires collaboration between governments, industry leaders, safety experts and businesses and is essential to driving change and creating a culture of safety in the nation’s workforce.
Strengthening infrastructure safety in manufacturing
Pointing out India’s growing attractiveness as a global manufacturing industry, which is critical to India’s growth trajectory, Bhardwaj said, “Foreign direct investment in the country has increased significantly by around 69% over the past 10 years. Along with this, there is a great demand for infrastructure development, and the government is making significant investments in this area.
At the same time, increasing the scale of manufacturing in India also requires expanding safety with modern safety standards. “India is a great place to set up a manufacturing business,” said Srivats Ram, Managing Director, Wheels India and Chairman, CII, Tamil Nadu. “However, as we grow and become more competitive, it is essential that we instill a culture of safety in our manufacturing operations to ensure safe growth.”
India’s competitive advantage lies in its abundance of skilled talent, but by incorporating safety and skills development into manufacturing operations, we can create a safer and more efficient industry for long-term success.
Electrical safety: Shaping the future of Indian manufacturing
The conclave will examine key aspects of electrical safety in Indian manufacturing, the sector’s readiness to meet global safety standards, the challenges faced by manufacturers, and how these challenges can be integrated into growth and global competition. We emphasized how it can be turned into an opportunity for power.
RA Krishnakumar of Chettinad Cement highlighted the positive changes in the sector’s approach to electrical safety. “We used to take a reactive approach to safety, but today we are more proactive,” he said.
Recognizing this trend, R. Balakrishnan, Vice President and Head of MEP Design at L&T, points out the challenges faced by MSMEs where cost constraints and lack of skilled manpower are significant barriers. I did. “The speed with which we adopt and implement safety measures will determine our global standing. But for small and medium-sized businesses, limited resources and awareness often impede progress. ” he said.
Regulation and compliance
The upcoming regulations of the Ministry of Heavy Industries (effective August 2025) aim to standardize Indian practices to global standards. Although the regulation covers more than 50,000 types of machinery, small manufacturers may face challenges in terms of compliance costs and timelines.
Gopa Kumar S., Chairman, National Federation of Electrical Safety Engineers, pointed out the need for strong safety audits and regulations in the backdrop of the country’s emergence as an export hub, pointing out that: . The team frequently assesses manufacturing facilities to ensure compliance with international requirements. ”The panellists therefore called on the government to introduce subsidies and incentives for factories with exemplary safety records.
Another recurring theme was the need to raise awareness of the importance of electrical safety. Bhushan Sawhney, President and Chief Business Officer of Polycab, put it succinctly during a fireside chat: “India needs to bring in a safety culture that is different from having procedures and processes. This means that when people go about their daily jobs, they think about the safest way to do their jobs. If you’re engaged, you’ve probably noticed a difference in the way things are done today compared to, say, 10 years ago.”
Mr. Sawhney reiterated the importance of encouraging greater safety awareness in the manufacturing sector. “Governments should prioritize safety measures and reward industries and factories that do good work. Raising awareness about the importance of safety is equally important,” he stressed. “Surakshit Bharat can only be achieved if safety starts with the manufacturers,” he added.
The role of automation, cables and smart technology
This requires three actions, notes A. Thanapal, Assistant Regional Officer, MI Fire E, Gl Fire E (UK), Tamil Nadu Fire and Rescue Department. “In Tamil Nadu, nearly 814 industries faced fire incidents, of which 502 had electric shock hazards. How can this be avoided? Electrical safety It’s all about applying the two Es.
India has a long way to go to meet global manufacturing standards. Challenges remain, including legacy machinery, outdated switchgear, and low-quality components. However, innovation and technology can play an important role in bridging this gap. Polycab representatives also asserted that manufacturing organizations can quickly overhaul safety measures by automating and transforming process controls using IoT-enabled devices and advanced cables and wires. I will. These smart technologies can reduce electrical accidents, increase productivity, create safer workplaces, align Indian factories with international benchmarks and enhance the reputation of Indian manufacturing.
Building a culture of electrical safety in manufacturing
While electrical safety is emerging as the foundation of global competitiveness in India’s rapidly advancing manufacturing industry, every step in building a strong safety culture requires a collective effort that must be rigorously must be shaped by standards, open communication and forward-thinking innovation.
According to Venkatesu C, Chairman, Electrical Safety, FSAI, it all needs to start with the basics of integrity testing. “Integrity testing ensures that not only the cable, but also the accessories used, can withstand adverse conditions,” he explained. This principle forms the foundation and ensures that safety starts with the smallest components and builds upward.
However, safety isn’t just about equipment; it’s also about empowering people. At FLSmidth Cement, safety has become a community effort, reveals Manufacturing Director Krishnamoorthy Rathinavel. “We share information with all employees in their local language. Regular weekly meetings with blue-collar workers are helpful. We hold monthly safety community meetings to review improvements, initiatives, and , discuss safety culture practices.”
R. Gobinath of Optimal MEP Consultants pointed out the vital role that MEP professionals play in bridging technical challenges and reality. “Consultants sometimes have to take a stand. Codes exist, but adapting them to the client will improve understanding and avoid problems such as recurring lithium accidents.” he reflected, emphasizing the need to balance compliance and innovation.
Insights from Nikhil Jaisinghani, Executive Director of Polycab, took the discussion in an important direction. Mr. Jaisinghani also emphasized the importance of the industry addressing challenges in implementing new technologies. It is important to proactively resolve these issues to prevent safety deficiencies and maintain progress. By adopting electrical safety measures, India can not only improve safety but also build a reputation as a global manufacturing hub. As Mr. Jaisinghani aptly stated, “Safety is hygiene. It’s not what you expect. It’s there, it has to be there, and there can be no question about it.” there is no.”
As the Infrastructure Safety Campaign has shown, in manufacturing, electrical safety is not a luxury or an afterthought, but a fundamental element that must be integrated into every design, system, and protocol.
