It was a typical afternoon at Tesla’s new Gigafactory near Austin, Texas. Engineers were doing final checks on the robotic production lines that would soon be assembling the electric car maker’s latest models. But one routine systems test soon turned dangerous when a large industrial robot suddenly and inexplicably turned on a human coworker.
John Smith, a 35-year-old robotics software engineer, was helping to troubleshoot issues on one of the cell welding stations. Two six-armed robots had been manually powered down so that Smith and another engineer could access the machinery for maintenance. “We had isolated the electrical current to those two robots to ensure their safety locks were engaged before we started working,” said Smith.
As the engineers examined some code on a control computer, a third robot nearby remained active without their knowledge. The robots, which can weigh over a ton and move with lightning speed, are designed to seamlessly coordinate motions duringvehicle assembly. But on that afternoon, one of the robots malfunctioned and turned towards the unsuspecting workers.
“I heard mechanical whirring and looked up to see the robot lunging right at me. It was like something out of a horror movie,” said Smith. “It struck me with one of its giant metal claws and I fell to the floor. Then it pinned me down and started digging into my arms with its other arms. There was an intense pain and I noticed blood pooling around me.”
Smith’s coworker Rick Anderson, 43, was standing nearby and saw the whole incident unfold. “As soon as I noticed the robot attacking John, I slammed on the emergency stop button on the control panel to disable it,” said Anderson. But even after being shutdown, it took a few moments for its large actuators to fully power down. It was a terrifying scene – I’ll never forget the image of my friend struggling under that machine.”
After being freed, Smith left the factory floor bleeding profusely but conscious. A medical report reviewed by The Information confirms Smith suffered “lacerations and cuts” on his left hand and other parts of his body from the robot attack. He was treated at a local medical center for non-life threatening injuries. Tesla reported the incident to federal workplace safety regulators as required by law.
Experts say robot malfunctions at industrial facilities, while uncommon, are concerning but understandable given the complex systems involved. These automated machines operate in fast, complicated environments and tiny software flaws or undetected hardware issues can sometimes lead to unpredictable behaviors,” said Professor Daniela Amodei of OpenAI, who researchesAI safety.
She added that advanced robotics are still prone to failures just like any complex machine. “The key is putting proper safeguards, monitoring, and emergency stop protocols in place. And reporting all incidents transparently so lessons can be learned to avoid future accidents.” Tesla stressed safety is a “top priority” but declined to provide any comments about the specific robot attack incident.
Some current and former Tesla employees anonymously expressed worries to The Information about other poor safety practices observed at the new Gigafactory. One said robotic arms have come “frighteningly close” to striking workers on occasion. Another saw robotic welders emitting showers of sparks near people. And tripping hazards from cables and tubes reportedly dotted the crowded factory floor at times.
However, the actual injury rate reported at the Tesla plant does not currently seem abnormal for a large-scale automotive factory. Federal data from 2021 – the latest available year – show occupational injury incidents at the Tesla factory occurred at a rate of around 5 per 100 full-time workers. That matches the industry average for motor vehicle manufacturing. But given Tesla’s heavy reliance on automation, some argue injury risks could be further reduced through innovative approaches.
John Smith has recovered from his physical wounds but still experiences flashbacks from the attack. Even simple tasks like installing software can make me anxious now thinking a robot might turn on me at any moment,” he said. While proud generally of Tesla’s mission to sustainable transportation, Smith is considering other job opportunities that don’t involve direct work alongside robots. His experience highlights the human toll of even small failures in advanced manufacturing technologies.
As robotics integrate further into workplaces, some experts say companies may need to re-think their safety culture and put people’s well-being above tight production timelines. More comprehensive staff training on automated system failures and lockouts could also help minimize future incidents. For now, Tesla and other industry leaders continue striving for the delicate balance of high-speed assembly and protecting the humans working alongside super-intelligent machines.
With immense promise but also inherent dangers, collaborative robotics will likely see more growing pains and worker injuries unless companies proactively prioritize safety culture, oversight and swift reporting of close calls and malfunctions. As robot co-workers become ever more dexterous and autonomous, keeping humans out of harm’s way remains an unsolved challenge – but one that will increasingly determine public trust in the future of automated industry.
