A Guide to Understanding and Preventing OSHA’s Top 10 Violations from 2023

Effective safety measures are vital for any company’s success. However, some businesses face recurring safety challenges, leading to preventable injuries and penalties. This article explores OSHA’s top 10 most frequently violated standards of 2023 and provides valuable strategies organisations can implement today to avoid them.

OSHA’s 2023 top 10 violations: A closer look

Comparing OSHA’s top 10 violations: 2022 vs 2023

• Persistent challenges
• Notable shifts

A strategic approach to preventing OSHA violations

• Enriched training programmes
• Proactive safety audits
• Cultivating a culture of safety
• Leveraging safety technology

Integrating advanced technology for enhanced workplace safety

OSHA’s 2023 top 10 violations: A closer look

Worker safety in the US has seen positive progress: from an average of 38 worker deaths daily in 1970 to 15 in 2022. Similarly, the rate of workplace injuries and illnesses has dramatically decreased, moving from 10.9 incidents per 100 workers in 1972 to 2.7 per 100 workers in 2022. However, despite this substantial progress, there is still significant room for improvement. 

The Occupational Safety and Health Administration (OSHA) released its annual overview of the top 10 most frequently violated standards for 2023. This annual list highlights the persistent challenges industries face in ensuring a safe working environment. The ten most commonly cited standards for the 2023 fiscal year were: 

1. Fall protection – General requirements (1926.501): Topping the list with 7,271 violations, this category underscores the critical need for comprehensive fall prevention strategies and systems in construction and other high-risk industries.

2. Hazard communication (1910.1200): With 3,213 violations, the continued prominence of hazard communication highlights the ongoing issues of properly informing employees about the dangers present in their workplace and taking the necessary precautions.

3. Ladders (1926.1053): Ladder safety remains a significant concern, evident from 2,978 citations. This points to the need for better training and adherence to safety standards when using ladders in construction.

4. Scaffolding (1926.451): Close behind, with 2,859 violations, scaffolding issues continue to pose risks for fall injuries, emphasising the importance of secure and correctly installed scaffolding systems.

5. Powered industrial trucks (1910.178): This category saw a rise to 2,561 violations, indicating issues with the operation and maintenance of forklifts and other powered industrial trucks.

6. Lockout/tagout (1910.147): With 2,554 citations, the slight increase in lockout/tagout violations stresses the critical nature of controlling hazardous energy during machinery maintenance.

7. Respiratory protection (1910.134): Accounting for 2,481 violations, this category’s presence underscores the essential need for proper respiratory protection in environments with hazardous airborne particles.

8. Fall protection – Training requirements (1926.503): Not far behind, with 2,112 violations, this indicates a gap in educating workers about fall hazards and prevention methods.

9. Eye and face protection (1926.102): With 2,074 violations, the necessity for eye and face protection in preventing serious injuries is highlighted.

10. Machine guarding (1910.212): Rounding out the list, with 1,644 violations, the continued need for guarding devices on machines to protect operators and others from hazards is emphasised.

This list reflects persistent safety issues that demand attention. Let’s look closer to understand how these issues have evolved from the previous year.

Comparing OSHA’s top 10 violations: 2022 vs 2023

A comparative analysis of the 2022 and 2023 lists reveals persistent challenges and notable shifts. 

Persistent challenges

• Fall protection – General requirements: Retaining its position at the top, the rise in fall protection violations from 5,260 in 2022 to 7,271 in 2023 signals a deep-rooted challenge in adequately safeguarding workers against fall hazards. This uptick might reflect the US construction industry’s rapid expansion and the pressures of meeting deadlines. This pressure can sometimes lead to oversight in implementing comprehensive fall prevention strategies, especially in the wake of increased urban development and infrastructure projects.

• Hazard communication: The increase in hazard communication citations from 2,424 to 3,213 underscores a persistent gap in properly managing chemical safety information. Recent introductions of new chemicals and materials in manufacturing and other sectors, along with regulatory updates, may complicate the adherence to hazard communication standards. This trend indicates a need for more dynamic and effective training protocols that keep pace with these changes.

• Ladders and scaffolding: The consistent citation of ladder and scaffolding violations points to enduring risks in working at height. Despite awareness, the slight variations in violations suggest challenges in adapting safety practices to the diverse and evolving nature of construction and maintenance work. This could be influenced by the increasing complexity of architectural designs and the push for renovation in urban spaces, which demand more sophisticated scaffolding solutions and skilled usage.

Notable shifts

• Powered industrial trucks: The climb in violations for powered industrial trucks suggests a growing concern. This trend may be partly due to the surge in e-commerce and warehouse operations, driven by recent shifts in consumer behaviour towards online shopping. The expansion of distribution centres has necessitated more frequent use of these trucks, possibly outpacing the implementation of rigorous training programmes and regular equipment checks.

• Respiratory protection: The drop in ranking for respiratory protection, despite an increase in violations, might hint at differential enforcement or prioritisation efforts across sectors. However, it remains a significant risk area, perhaps reflecting the ongoing impact of global health challenges, such as the Covid-19 pandemic, on respiratory safety standards. Workplaces may be grappling with maintaining high levels of protection amidst changing guidance and the evolving nature of respiratory hazards.

• Lockout/tagout: The slight rise in lockout/tagout violations highlights its importance in worker safety, emphasising the complexity of ensuring machinery is deactivated during maintenance. This persistent challenge could be exacerbated by the introduction of more sophisticated machinery and automation in manufacturing, requiring workers to adapt to new lockout/tagout procedures. The steady ranking indicates ongoing efforts to improve compliance but also points to the need for enhanced training that keeps pace with technological advancements.

Having navigated through the comparisons and understood the persistent and shifting challenges in workplace safety, it’s time to consider strategic approaches to mitigate these risks effectively.

A strategic approach to preventing OSHA violations

The persistence of certain violations on OSHA’s annual lists signals enduring challenges within workplace safety practices and illuminates the path forward. A comprehensive, multilayered strategy is critical in bridging the gap in training, communication and the practical implementation of safety measures. Here’s how organisations can adopt a more dynamic approach to mitigate these risks effectively.

Enriched training programmes

To genuinely reduce the occurrence of violations, safety training must evolve into an immersive experience:

• Customised content: Develop training modules that resonate with your workforce’s specific roles and environments. Tailoring content to address your industry’s particular violations can make training more relevant and impactful.

• Interactive sessions: Incorporate hands-on training and simulations that mirror real-life scenarios. Interactive learning helps cement safety protocols in workers’ memories, ensuring they’re better prepared when faced with potential hazards.

• Continuous learning: Safety education is not a one-off but a constant journey. Implement regular refresher courses and updates to keep safety front of mind and adapt to new standards or technologies.

Proactive safety audits

A forward-thinking safety programme is proactive, not reactive. Regular safety audits are essential in identifying and rectifying potential hazards:

• Scheduled and random inspections: Blend both planned audits and random checks to get an accurate picture of daily operations and compliance levels.

• Cross-functional teams: Involve employees from various departments in the audit process. This approach not only fosters a culture of safety but also brings diverse perspectives to identifying and solving safety issues.

• Actionable feedback: Ensure that the findings from audits lead to concrete actions. Prioritise issues based on risk level and track improvements over time to ensure compliance and safety enhancements.

Cultivating a culture of safety

At the core of preventing OSHA violations is the cultivation of a safety-first culture:

• Leadership engagement: Safety starts at the top. When leaders actively participate in and advocate for safety initiatives, it sets a tone that resonates throughout the organisation.

• Employee involvement: Empower workers by involving them in safety discussions, decision-making and problem-solving. An inclusive approach ensures that safety measures are practical and universally adopted.

• Recognition and accountability: Recognise and reward compliance and proactive safety measures. Similarly, establish clear consequences for violations to underscore the importance of safety.

Leveraging safety technology

Technology is integral to our daily operations, and leveraging innovative solutions can significantly enhance workplace safety:

• Real-time monitoring: Utilise wearables that monitor vital signs and environmental conditions, providing instant alerts to prevent heat stress, fatigue and other physical stress-related risk factors.

• Data-driven insights: Apply AI and analytics to interpret safety data, identifying trends and predicting potential violations before they occur. This proactive stance allows for timely intervention and tailored safety strategies.

• Integrated safety platforms: Adopt platforms that consolidate safety management into a single, accessible tool. Such systems can track compliance, manage training records and facilitate incident reporting and investigation, streamlining safety management processes.

Implementing the strategies mentioned above is the first step towards preventing the most frequent OSHA violations in the US and beyond. Let’s explore how particular technological solutions, such as those provided by Bodytrak®, offer a promising path to meet and exceed compliance standards.

Integrating advanced technology for enhanced workplace safety

Integrating advanced technology is a game-changer in the quest to mitigate recurring OSHA violations and elevate workplace safety standards. The solution from Bodytrak  offers a sophisticated blend of real-time physiological monitoring and machine-learning analytics that tackle the root causes of common violations.

For example, for operators of powered industrial trucks, fatigue and lack of alertness pose significant risks. Bodytrak 1 is the first non-invasive in-ear safety solution that precisely monitors heat stress, fatigue and noise exposure to prevent workplace incidents. Detecting early signs of these risk factors enables managers to make informed decisions about scheduling breaks or rotating drivers to maintain high levels of alertness and safety. 

Don’t wait for the next incident or violation to reflect on what could have been done. Take action now to protect your workforce and set a new standard in safety compliance. Reach out to Bodytrak today to explore how our solutions can transform your safety practices and help your organisation move beyond compliance to excellence in workplace safety.