The Most Common OSHA Violations in Manufacturing

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Whether your company handles food processing, machining, batch processing or another type of manufacturing, you want to keep the employees at your plant safe. Manufacturing can be a hazardous business. In 2019, 15% of all private industry nonfatal injuries and illnesses in the United States took place in manufacturing, according to the Bureau of Labor Statistics.

Injuries can negatively impact your workers’ health and your company’s productivity. You may need to pay workers’ compensation or face labor shortages. You could also be subject to fines if the injury stemmed from a workplace violation.

How can you make your workplace safer for employees? When you learn about the most common violations cited by the Occupational Safety and Health Administration (OSHA), you’ll know what to look for to keep your business thriving and protect your employees.

What is OSHA?

OSHA is a regulatory agency that has overseen the occupational health and safety of employees since 1970. Congress gave OSHA the power to inspect workplaces to ensure companies follow federally mandated safety standards. OSHA examines working conditions and provides training and assistance to help workplaces improve their safety practices.

OSHA enforces regulations, with oversight of issues including:

  • Personal protective equipment.
  • Hazardous chemicals.
  • Quality of air.
  • Working hours.
  • Workplace violence.

Most-Cited Violations in Manufacturing

What are the four types of OSHA violations most commonly seen in manufacturing? Here are the top examples.

Worker driving a forklift in a warehouse moving boxes

 

1. Machine Guarding

Machine guarding transgressions are the most common OSHA violation. Industrial machines pose the biggest potential hazards if workers don’t know how to operate them properly. Carelessness or not following safety standards can also result in serious injury at machines, which generate sparks or may have saws, cutters or mills. OSHA mandates machine guarding, which institutes specific protections around machines to keep workers from getting hurt.

2. Lockout/Tagout

If works don’t correctly control machine energy when servicing a machine, they could get seriously hurt by steam, electricity or chemicals. Injuries may include burns, electrocution, lacerations or amputation. Not using proper procedures to control energy falls short of complying with lockout/tagout (LOTO) standards. For example, workers should de-energize a hydraulic press before working on it.

3. Hazard Communication

Employees should know when they’re exposed to potentially dangerous chemicals. An employee who doesn’t know they’re handling hazardous chemicals might not take the necessary safety precautions or be lax with a hazardous substance. Such chemicals might include:

  • Acids.
  • Solvents.
  • Pesticides.
  • Lead or mercury.
  • Glue.

Employers should offer training to employees regarding how to handle dangerous materials. Failing to track this training or not submitting documentation of your hazardous chemical communications can result in OSHA violations.

4. Respiratory Infection

Personal protective equipment (PPE) choices are some of OSHA’s most complex standards. Manufacturers must select what type of protection their employees wear based on the type of hazards the workers face exposure to, such as dust, and a host of other factors, including:

  • Potentially flammable agents.
  • What the employee is doing.
  • Length of exposure.
  • Toxicity of the substance.

Every workplace has different requirements in this area, so you can’t look at what someone else has done to cull your guidelines. You need to consider your own unique workplace. OSHA violations occur when not all respiratory hazards are identified or planned for, equipment is not stored or maintained carefully, employees lack training for wearing the equipment or equipment fits poorly.

How to Prevent OSHA Violations in the Workplace

Here are a few ways you can prevent the top four OSHA violations:

  • Machinery: Inspect machinery on your plant floor and ensure it has the right safeguarding. Provide employees with training before they use the equipment.
  • Lockout/tagout: Institute an energy control program and only employ lockout or tagout devices that suit the machinery in question. Perform regular inspections to ensure logouts/tagouts work.
  • Hazard communication: Post safety data sheets that detail chemicals’ dangerous properties at worksites. Create a hazcom program that breaks down all the chemicals used at your workplace and have all employees undergo hazardous chemical training.
  • Respiratory infection: If possible, attempt to minimize airborne hazards. Offer workers respirators and teach them how to use their equipment properly. Give all workers as many breaks as they need while working with or around dust or gas.

MANTEC Provides Resources for Avoiding OSHA Violations

MANTEC can assist your workplace with your OSHA compliance. Learn more about our process improvement opportunities and download our guide today.

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