Top 10 OSHA Violations in Manufacturing

What are the Top OSHA Violations in Manufacturing?

The top Occupational Safety and Health Administration (OSHA) violations in manufacturing typically stem from the inherent risks of working with heavy machinery, hazardous chemicals, and fast-paced production lines. These violations highlight critical gaps that can lead to severe injuries, operational downtime, and significant financial penalties.

For enterprise-level facilities, proactively addressing these problem areas is essential to maintaining a safe work environment and ensuring compliance with OSHA standards.

Impacts of Noncompliance

Failing to follow OSHA standards can put workers in danger and expose  employers to serious penalties. Let’s take a closer look at the real consequences of noncompliance:

• Financial Losses: Overlooking safety regulations in manufacturing can lead to costly fines and penalties that impact the bottom line. OSHA penalties can range from around $16,0000 to over $100,000 per violation, with additional daily fines for unresolved issues.

• Injuries and Fatalities: According to OSHA, manufacturing violations contributed to a devastating toll in 2023, with 5,283 worker fatalities reported—equivalent to 3.5 deaths per 100,000 full-time workers. This stark statistic underscores the severe consequences of safety violations in the industry.

• Operational Disruptions: Accidents and injuries can disrupt operations, affecting a company’s productivity and efficiency. It may cause delays, reduced output, workers’ compensation claims, and even the risk of business closure.

• Legal Consequences: Violations of OSHA standards endangers employees  and can result in serious  legal repercussions for companies. In extreme cases, companies may face criminal charges, fines, and civil lawsuits from affected employees or their families.

• Worker Morale: When safety protocols aren’t upheld, it can create a negative work environment that leaves employees feeling unsafe and unappreciated. It can significantly impact worker morale, leading to decreased productivity, increased turnover rates, and difficulty attracting new talent.

• Reputational Harm: Workplace accidents can hurt a company’s reputation, especially in the age of social media. News of an injury or death can spread fast, leading to public backlash and damaging the company’s image.

Top 10 OSHA Violations in Manufacturing

Below are the top 10 OSHA violations in manufacturing—essential insights to help you stay ahead of risks and reinforce strong manufacturing compliance across your operations:

Top 10 OSHA Violations in Manufacturing

OSHA Violation #1: Lockout/Tagout (LOTO) (Hazardous Energy Control)

Standard Number: 19100147

A recent report reveals a 29 percent increase in LOTO violations from 2022 to 2023, with the manufacturing sector being the hardest hit. Lockout/tagout procedures are essential to prevent unexpected machine start-up, protecting workers from potentially life-threatening accidents. Strengthening protocols in this area is a critical step in managing hazards effectively.

OSHA Violation #2: Machine Guarding

Standard Number: 19100212

Machine guarding involves protective measures to protect workers from hazardous machine parts, sharp edges, and moving components. Machines without proper safeguards expose employees to serious injuries like amputations, crushing, and lacerations. OSHA reports around 18,000 injuries and over 800 fatalities annually among workers using or maintaining machinery.

OSHA Violation #3: Powered Industrial Trucks

Standard Number: 19100178

Forklifts and similar equipment are essential for factory operations but can be dangerous if not used safely. In 2024, violations involving forklifts resulted in fines exceeding $8 million. To reduce the risks linked to these machines in manufacturing settings, consistent inspections and ongoing employee training are essential.

OSHA Violation #4: Hazard Communication

Standard Number: 19101200

Clear communication about hazardous chemicals is essential to protect workers from exposure. OSHA requires labels, safety data sheets, and training to ensure everyone understands the risks. A strong hazard communication plan meets compliance standards and builds trust and accountability within your team.

OSHA Violation #5: Occupational Noise Exposure

Standard Number:19100095

The Centers for Disease Control (CDC) estimates that 22 million workers are exposed yearly to harmful noise. The most common source of occupational noise exposure in manufacturing environments is from machinery and equipment. That’s why OSHA requires employers to have a hearing conservation program if noise levels exceed 85 decibels over an 8-hour workday.

OSHA Violation #6: Process Safety for Hazardous Chemicals

Standard Number: 19100119

Facilities handling highly hazardous chemicals must have strict process safety management in place. It includes hazard analysis, operating procedures, and emergency planning to prevent catastrophic incidents. Investing in robust systems here is essential to mitigate the unique risks posed by chemical-intensive operations.

OSHA Violation #7: Electrical Wiring and Components

Standard Number: 19100305

Electrical hazards, such as improper wiring and faulty components, can lead to fires, electric shock, and equipment failure. These hazards are hazardous in chemical processing plants due to flammable and dangerous chemicals. Proper installation of electrical wiring, following OSHA guidelines, is essential for workplace safety.

OSHA Violation #8: Mechanical Power Transmission

Standard Number: 19100219

Unprotected belts, gears, and pulleys are serious hazards if left exposed. These mechanical power transmission parts have the potential to cause serious injuries, such as amputations and fractures. Regular equipment reviews help maintain compliance and protect workers from avoidable accidents.

OSHA Violation #9: Fall and Falling Object Protection

Standard Number: 19100028

Falls are one of the most common causes of workplace injuries in manufacturing. Every year falls from ladders, platforms, and other elevated areas cause thousands of injuries and dozens of fatalities. OSHA’s regulations require employers to protect workers from fall hazards by providing adequate fall protection equipment and training.

OSHA Violation #10: Respiratory Protection

Standard Number: 19100134

When employees are exposed to harmful dust, fumes, or vapors, respiratory protection becomes essential. OSHA requires a comprehensive program that includes proper mask selection, fit testing, and regular training. A strong respiratory protection plan is critical for long-term worker health and operational continuity.

Best Practices for Prevention and Compliance

Employers can follow several best practices to ensure compliance with OSHA standards and protect employees from respiratory hazards.

• Conduct Regular Inspections and Risk Assessments: Regular risk assessments help catch potential hazards early and keep safety practices current.

• Develop and Implement Comprehensive Safety Policies: Clear, well-documented safety policies outline responsibilities and ensure everyone understands their role in maintaining a safe workplace.

• Build and Maintain a Hazard Communication Plan: A solid hazard communication plan clarifies chemical risks with proper labeling, safety data sheets, and ongoing employee training.

• Provide Appropriate Personal Protective Equipment (PPE): Providing the proper PPE and ensuring employees use and maintain it adequately protects them from workplace hazards.

• Deliver Ongoing OSHA Compliance Training: Consistent training informs employees about safety procedures, empowering them to handle risks confidently.

• Maintain Emergency Preparedness: A well-communicated emergency action plan ensures everyone knows what to do during fires, chemical exposures, or other emergencies.

• Ensure Availability of First-Aid Supplies: Easily accessible and fully stocked first-aid kits enable quick response when on-site injuries happen.

• Keep Accurate Records and Report Incidents: Thorough recordkeeping of incidents supports compliance efforts and helps drive continuous safety improvements.

• Apply Engineering and Administrative Controls: Engineering solutions and smart work procedures can significantly reduce exposure to workplace risks.

• Foster a Culture of Safety: Involving employees in safety initiatives and keeping communication open builds a strong safety culture that prevents accidents.