Understanding OSHA's Focus on Manufacturing
Manufacturing facilities consistently rank among the most frequently cited industries for OSHA violations. In 2025, manufacturers faced over $150 million in penalties, with many violations being entirely preventable through proper training and safety protocols.
The Top 10 Violations
1. Lockout/Tagout (LOTO) - 29 CFR 1910.147
The control of hazardous energy remains the most cited violation in manufacturing. Workers servicing or maintaining machines must be protected from unexpected startup or release of stored energy.
How to comply:
- Develop written energy control procedures for each machine
- Train all affected employees annually
- Conduct periodic inspections at least annually
- Use standardized locks and tags
2. Machine Guarding - 29 CFR 1910.212
Unguarded or improperly guarded machines cause thousands of amputations annually. Point of operation guards, barrier guards, and two-hand controls are essential.
How to comply:
- Conduct a machine guarding assessment
- Install appropriate guards on all points of operation
- Never allow guards to be bypassed or removed
- Document all guarding decisions
3. Respiratory Protection - 29 CFR 1910.134
From welding fumes to chemical vapors, manufacturing exposes workers to numerous airborne hazards requiring respiratory protection programs.
How to comply:
- Conduct exposure assessments
- Implement a written respiratory protection program
- Provide medical evaluations and fit testing
- Train employees on proper use and maintenance
4. Powered Industrial Trucks - 29 CFR 1910.178
Forklift accidents cause approximately 85 deaths and 34,900 serious injuries annually. Proper training and certification are mandatory.
How to comply:
- Train and certify all forklift operators
- Evaluate operators every three years minimum
- Conduct daily pre-operation inspections
- Establish traffic management plans
5. Electrical - Wiring Methods - 29 CFR 1910.305
Improper wiring, damaged cords, and missing covers on electrical panels create shock and fire hazards.
How to comply:
- Inspect electrical systems regularly
- Replace damaged cords and equipment immediately
- Ensure all junction boxes have covers
- Use appropriate electrical equipment for the environment
6. Hazard Communication - 29 CFR 1910.1200
Workers have a right to know about chemical hazards in their workplace. Incomplete Safety Data Sheets (SDS) and missing labels are common violations.
How to comply:
- Maintain a complete SDS library
- Label all secondary containers
- Train employees on chemical hazards
- Update the written HazCom program annually
7. Fall Protection - 29 CFR 1910.28
Falls from elevated surfaces, including mezzanines, platforms, and maintenance areas, require protection at four feet in general industry.
How to comply:
- Install guardrails on all open-sided platforms
- Provide fall protection for maintenance activities
- Train employees on fall hazards
- Inspect fall protection equipment regularly
8. Walking-Working Surfaces - 29 CFR 1910.22
Slips, trips, and falls on the same level account for 15% of all workplace injuries. Housekeeping and surface conditions matter.
How to comply:
- Implement daily housekeeping inspections
- Repair floor damage promptly
- Mark changes in elevation
- Keep aisles and walkways clear
9. Personal Protective Equipment - 29 CFR 1910.132
Failure to assess hazards and provide appropriate PPE leaves workers vulnerable to injury.
How to comply:
- Conduct a PPE hazard assessment
- Document the assessment in writing
- Provide PPE at no cost to employees
- Train on proper use and limitations
10. Noise Exposure - 29 CFR 1910.95
Manufacturing noise levels frequently exceed the 85 dBA action level, requiring hearing conservation programs.
How to comply:
- Monitor noise exposure levels
- Implement engineering controls where feasible
- Provide hearing protection and training
- Conduct annual audiometric testing
The Insurance Connection
OSHA violations directly impact your insurance costs. Citations signal poor risk management to underwriters, often resulting in:
- Higher workers' compensation premiums
- Increased Experience Modification Rates (X-Mod)
- Difficulty obtaining coverage
- Higher deductibles and self-insured retentions
Taking Action
At Core Brokers, we help manufacturers develop comprehensive safety programs that reduce both OSHA exposure and insurance costs. Our risk management team can conduct facility assessments and help you prioritize improvements.
Contact us for a complimentary safety review of your manufacturing operations.