Trip Hazards and Cable Management in Busy MRO Areas
Time Wasted for the Utility Industry on Cable Setup and Cleanup During MRO Activities
CASE STUDYTrip Hazards and Cable Management in Busy MRO Areas
If you manage a busy warehouse, factory, or job site, power access and cable management are essential to smooth operations. A tangled mess of extension cords on the floor isn't just a tripping hazard—it costs you time, damages equipment, and creates safety risks.
At KH Industries, we see this challenge every day. One of our recent clients—a major industrial manufacturing and assembly plant—was experiencing these exact problems on their production floors. Here's how transitioning to KH Industries' industrial retractable cord reels changed the game for them—and how it can transform your facility.
THE PROBLEM
Like many industrial environments, their facility relied heavily on power tools and mobile equipment. What they found was that traditional power cord management was causing multi-layered issues:
01
Frequent tripping hazards leading to workplace injuries
02
Time wasted untangling cords before each use
03
Increased wear and tear on cables
04
Cords left on the ground were being run over by forklifts
05
Inefficient workspace layout due to limited outlet access
This wasn't just an inconvenience. It was costing them money, risking employee safety, and hurting productivity.
The Solution: KH Industries Industrial Retractable Cord Reels
Working with an electrical distributor, the facility installed KH Industries RTB and RTF Series industrial retractable cord reels in key MRO and maintenance areas.
The reels were mounted overhead — either on the ceiling or high on the wall — directly above workbenches, service bays, and equipment that required frequent power or air access.
Why Retractable Cord Reels?
Retractable cord reels give technicians easy access to what they need without leaving cords on the floor. When the job is done, the cable retracts automatically, keeping the area clean and clear.
In this case, the reels:
- Kept cords and hoses off walking surfaces
- Allowed technicians to pull out only the length needed
- Stored cables safely when not in use
- Reduced wear caused by dragging and crushing
KH Industries reels were chosen for their heavy-duty construction and reliability in demanding industrial environments.
THE RESULTS
01
Fewer Trip Hazards and Safer Work Areas
With cords no longer lying across walkways, the most immediate improvement was safety. Trip hazards were greatly reduced, and near-miss reports tied to loose cords dropped. In fact, within the first six months of installing retractable cord reels, the facility reported a 65% reduction in trip- and near-miss incidents related to cords and hoses in MRO areas.
By keeping cables off the floor and out of walkways, safety managers were able to eliminate one of the most common hazards identified in prior incident reports.
Clear floors also made it easier to define safe walk paths and keep MRO areas organized.
02
Clear floors also made it easier to define safe walk paths and keep MRO areas organized.
Housekeeping and safety audit scores improved after the reels were installed. Safety and housekeeping audit scores in affected MRO zones improved by approximately 30% following installation.
Auditors noted:
- Clear walking paths
- Consistent cable management practices
- Fewer temporary cords left in active areas
This helped the facility address previous audit findings and support ongoing OSHA compliance efforts.
For contractors, this is an important point: retractable cord reels don't just improve day-to-day operations — they also support OSHA compliance and long-term safety programs.
03
Faster, More Efficient Maintenance Work
Technicians no longer had to search for cords, untangle hoses, or drag cables out of the way. Power and air were always available where needed, without creating obstacles. This led to smoother workflows and less downtime between tasks. Maintenance supervisors reported that common service tasks were completed about 20% faster once cords and air lines were stored overhead and always ready for use.
Technicians spent less time:
- Locating power sources
- Untangling cords and hoses
- Moving cables out of the way
That time savings added up across multiple shifts and workstations.
04
Reduced Cable and Hose Replacement Costs
By storing cords overhead and out of traffic areas, the facility saw a 40% reduction in damaged cables. Fewer cords were crushed by carts or run over by equipment, which reduced replacement costs and unplanned maintenance. In many cases, the cost savings with the cord reels paid for themselves simply by extending the life of the cables and hoses they protected, sometimes within the first year.
Why This Matters for Distributors and Contractors
This project is a good example of how a simple change in cable management can have a big impact. These quantifiable results helped move a project from "nice improvement" to justified investment.
01
A proven way to improve workplace safety
02
An easy add-on for MRO, maintenance, and production areas
03
A solution that helps customers reduce long-term costs
04
A product that supports safety audits and compliance goals
It's also an easy upgrade for existing facilities, with minimal disruption during installation.
— WHY KH INDUSTRIES
KH Industries designs and manufactures industrial-grade cord reels built for real-world use. These reels are made to handle the demands of MRO environments, where durability and reliability matter.
Key advantages include:
- Heavy-duty construction
- Multiple mounting options
- Configurations for power, air, and data
- Long service life in harsh industrial settings
For electrical distributors and contractors, KH Industries cord reels provide a dependable solution that delivers measurable results for end users.
VIEW LATEST CASE STUDIES
Extending Cord and Tool Life in Freight Rail MRO with Industrial Retractable Cord Reels
CASE STUDY
Improving Event Turnover, Safety, and Power Access at a Major Metropolitan Convention Center
CASE STUDY
