OSHA’s Top Violations for 2023
A look back at the year's highest safety violations
Ensuring workplace safety is a continuous pursuit, particularly in manufacturing and warehousing industries, where risks abound. The annual release of the Occupational Safety and Health Administration’s (OSHA) Top 10 list of the most frequently cited workplace safety violations serves as a beacon for operations to navigate potential hazards.
In this deep dive, we focus on details for each of the Top 10 violations for fiscal year 2023, offering insights and actionable strategies to enhance material handling safety protocols.
10. Machine guarding
Securing the 10th position on OSHA’s list, machine guarding underscores the critical need for protective barriers in the workplace. The fiscal year 2023 witnessed a noteworthy increase in violations, from 1,370 to 1,644. This spike is particularly prevalent in manufacturing companies, where citations were most frequent.
Machine guarding encompasses the imperative need for barriers shielding workers from point-of-operation hazards, including rotating parts, flying chips, and sparks. In manufacturing settings, employees working in proximity to such machinery express heightened concerns. In the world of warehousing, where conveyors and robots proliferate, the risk of worker injury escalates. Employing rigorous safety measures, especially in high-risk areas, can mitigate the potential dangers associated with this violation.
9. Eye & face protection
Holding firm at the 9th position, violations for eye and face protection surged to 2,074, a rise of almost 700.
The manufacturing sector faces specific challenges, with flying particles and chemical gases posing significant threats to workers’ eyes and faces. The emphasis on mandatory protective eyewear is crucial, and additional measures such as spill control equipment further enhance chemical safety. By maintaining adherence to these safety protocols, an operation can minimize the risk of eye and face injuries.
8. Fall protection: training requirements
Retaining its position on OSHA’s list, fall protection: training requirements garnered 2,112 violations in FY 2023, showcasing an increase from the previous year’s 1,556. Roofing contractors, once again, were prominently cited.
The intersection of inadequate training and suboptimal equipment for fall protection underscores the significance of this violation. Robust training programs and the deployment of appropriate safety gear are critical elements in preventing accidents related to falls. A conscientious approach to training can bridge the gap in understanding the risks associated with falls and the proper preventive measures.
7. Respiratory protection
Slipping to the 7th spot, Respiratory Protection saw an uptick in violations, totaling 2,481 in FY 2023. Operations with high usage of paint areas were the most cited.
Though lower in rank, the importance of respiratory protection cannot be understated. Vigilance in equipping workers with proper respiratory gear and proper adherence to safety protocols are paramount. Companies, especially in high-risk sectors, should consistently reinforce the significance of respiratory protection to minimize potential health hazards.
6. Lockout/Tagout
Maintaining its 6th place, Lockout/Tagout (LOTO) witnessed a notable increase in violations, climbing from 1,977 in FY 2022 to 2,554 in FY 2023. This category also recorded the second-highest number of willful violations on the list.
LOTO is a crucial part of managing dangerous energy, with the main goal of preventing unplanned machine starts and energy discharges. Dealing with uncertainties in this area involves closely following set rules and prioritizing procedures to reduce risks and promote a safer workplace.
5. Powered industrial trucks
Climbing the ranks, powered industrial trucks claimed the 5th position, with violations surging from 1,749 in FY 2022 to 2,561 in FY 2023. Unlike many categories on OSHA’s list, this violation is not heavily concentrated in the construction industry and focuses more on warehousing and distribution, where forklifts are used to move products and items all around an operation.
Covering a spectrum of motorized transport methods, including fork trucks and lift trucks, this violation underscores the inherent dangers when powered vehicles operate within warehouses or factories. Proper training and the strategic deployment of safety equipment such as warning lights, automated gate systems, and guardrails can significantly reduce the risk of accidents involving industrial trucks.
4. Scaffolding
Ascending to the 4th spot, scaffolding violations experienced a substantial increase from 2,058 to 2,859 in FY 2023.
Safeguarding workers on scaffolding involves more than compliance; it demands a boots-on-the-ground approach. Ensuring the provision of guardrails and sufficient access to scaffolding surfaces is paramount. Departments should prioritize comprehensive scaffolding safety measures to navigate the complexities associated with this violation.
3. Ladders
Taking a significant step up in the rankings this year, ladders secured the 3rd position with 2,978 violations in FY 2023, a surge of over 800 from the previous year.
Establishing a dedicated ladder safety program is a fundamental step toward mitigating the risks associated with ladder use. Exploring alternative solutions, such as crossovers and platforms, can significantly reduce reliance on ladders. Initiatives like National Ladder Safety Month can serve as effective tools for keeping employees informed and safety-aware.
See: Ladder safety guide
2. Hazard communication
Holding onto the runner-up position, Hazard Communication (HazCom) violations increased by 789, totaling 3,213 in FY 2023. These citations emerged in roughly 10 percent of all OSHA inspections.
Effectively communicating hazards and adhering to HazCom guidelines are foundational elements in maintaining workplace safety. You want to prioritize clear and comprehensive hazard communication protocols to ensure that employees are well-informed and equipped to handle potential risks.
1. Fall protection: general requirements
For the 13th consecutive year, fall protection retains its dominance on OSHA’s list, with a staggering 7,271 violations in FY 2023. Not only did it account for the most violations, but it also registered the highest number of serious and willful violations.
Implementing a robust training system coupled with the strategic installation and use of various equipment, including guardrails, mezzanine gates, and of course fall protection gear is paramount to preventing costly injuries on the job. Identifying and focusing on areas with the highest concentration of falling hazards, such as shipping and receiving docks, is instrumental in tailoring safety measures to address specific risks.
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Evan Fleishacker