Most commonly cited OSHA violations and how safety audits can help

January 19th, 2022 by Dakota Software Staff

In an instant, a serious OSHA violation can cripple a business or destroy a company’s reputation. In February of 2021, the Occupational Safety and Health Administration (OSHA) published its preliminary list of the top 10 most frequently cited workplace safety standards for 2020. The list is a valuable asset for companies working towards improving their OSHA compliance but who may not know where to start.

Of the top 10 violations, five impact the General Industry. So, what are the most commonly cited OSHA General Industry standards?

1) Hazard Communication Standard (29 CFR 1910.1200)

OSHA’s Hazard Communication Standard mandates that employers must educate their workers in the identification and mitigation of the hazards associated with any chemicals they may encounter in their workplace. Chemical information must be available and understandable to workers through training and the availability of Safety Data Sheets (SDS).

Chemical importers and manufacturers must evaluate the hazards of their chemicals and provide labeling and SDS’s so that the end-user can understand the hazards and how to protect themselves and their coworkers.

Common OSHA violations:

• Not developing and maintaining a written HazCom program (1910.1200(e)(1))

• Not maintaining worker training (1910.1200(h)(1))

• Not labeling hazardous chemicals (1910.1200(f)(5))

• Not having the required copies of chemical safety data sheets in the workplace (1910.1200(g)(8))

2) Respiratory Protection (29 CFR 1910.134)

Each year hundreds of workers die from exposure to airborne hazards. Due to their work environments, a large number of workers in the United States are required to wear respirators on the job. The right respirator, when worn correctly, will protect employees from dust and chemical particulates in the air as well as low oxygen environments. Employees that are not properly protected from these hazards may develop cancers, diseases, and other respiratory illnesses which can be life-threatening.

Common OSHA violations:

• Not conducting a medical evaluation of employees (1910.134(e)(1))

• Not establishing a respiratory protection program (1910.134(c)(1))

• Not conducting fit testing (1910.134(c)(1)(iii))

3) Control of Hazardous Energy (lockout/tagout) (29 CFR 1910.147)

The results of a piece of machinery being accidentally energized while it is being worked on can be catastrophic. To ensure worker safety, it is crucial that potentially hazardous energy sources be controlled during the maintenance of equipment and machinery. The abrupt discharge of this energy, from hydraulic, chemical, electric, or mechanical sources, can result in serious injury or death to workers. Having strong Lockout Tagout procedures in place can help prevent a life-altering tragedy. OSHA requires that employers safeguard workers from hazardous energy sources and train employees on the proper steps to protect themselves.

Common OSHA violations:

• Not having an Energy Control Procedure (1910.147(c)(4))

• Not providing sufficient training (1910.147(c)(7))

• Not conducting an annual inspection of their energy control procedure (1910.147(c)(6))

4) Powered Industrial Trucks (29 CFR 1910.178)

Forklifts, also known as powered industrial trucks, are common in many industries. They come in a wide range of styles and sizes with each having its strengths and hazards. Some common accidents with powered industrial trucks are from lifts being driven off of loading docks, lifts tipping over, or lifts striking pedestrians. Employers are responsible for ensuring that anyone operating a lift is competent and has completed training and an evaluation.

Common OSHA violations:

• Not ensuring operator competence through training and evaluation (1910.178(l)(1)(i))

• Not recertifying operators every three years (1910.178(l)(4)(iii))

• Not removing damaged or unsafe lifts from service (1910.178(p)(1))

5) Machinery and Machine Guarding (29 CFR 1910.212)

Working around equipment with exposed moving parts can result in serious injuries. Protecting workers from these hazards is important and any machinery that can cause injury to workers must be protected. Failure to do so can result in severe hand injuries, amputations, burns, blindness, or even death.

Common OSHA violations:

• Not using guards to sufficiently protect workers from machine nip points, rotating parts, flying debris, and sparks (1910.212(a)(1))

• Not preventing employees from having their body in any machines danger zone during operation (1910.212(a)(3)(ii))

• Not properly securing fixed equipment to prevent moving during operation (1910.212(b))

How safety audits can help

OSHA’s top violation list shows us that there is room for improvement when it comes to compliance with workplace safety requirments. If you’ve noticed some deficiencies in your company's safety performance, adopting a strong safety audit program is a great place to start. When done properly, safety audits will help to identify gaps in your compliance status, increase worker awareness of hazards, and demonstrate your commitment to workplace safety. A systematic safety audit program and a diligent process for correcting deficiencies also demonstrates a good-faith effort by your company towards safety to regulatory agencies that may inspect your facility.

When conducting an audit as a gap analysis tool, Safety teams should strive for comprehensive audits prioritized around areas of operational risk. When auditors go to physical location to observe work being done, they should ask detailed questions of the employees working in those area to ensure that safety procedures are in place and understood and that proper training is being conducted. Having audit checklists that cover all safety objectives and site-specific regulatory requirements will help establish audit consistency and ensure auditors don't neglect any relevant requirments.

It's easy to see the benefits of safety audits, but managing and tracking audits and ensuring that findings are resolved can be challenging. Using state-of-the-art EHS audit software can simplify the process. Dakota Auditor allows for the testing and verification of your company's workplace EHS compliance. It not only captures all relevant regulatory requirements, but also allows users to develop unique checklists, evaluate past audit findings and data, build custom protocols, and create corrective action plans. Contact us today to find out all the ways Dakota can help you achieve your safety compliance goals.