The Most Common OSHA Violations We See Across Job Sites

(And How to Fix Them)

We have walked thousands of job sites, and the problems we find are fairly consistent.

Here are some of the issues we see the most and what to do about them before they turn into citations.

1. Missing or Inconsistent Inspections

This is likely the most common issue. Fire extinguishers haven’t been checked. Eyewash stations haven’t been flushed. Forklift inspections are getting skipped or not documented.

Fix: Put a simple system in place and stick to it. Same schedule, same process every time, and make sure it’s documented. This is an easy item to implement! Visit The Safety Store if you need inspection tags.

2. Safety Manual Doesn’t Match Current Business Operations

We see this regularly. A company has a safety manual, but it doesn’t reflect how work is actually being done at all.

That’s a problem, because inspectors compare your documentation to your operations.

Fix: Update your safety program so it actually matches your current job assignments, equipment, and workflow.

3. Training Happened, But There’s No Record of It

A lot of teams are doing the right thing with training their employees. But training has to be recorded, or it essentially never happened.

Fix: Track ALL training - EVERYTHING. Make sure it’s tied to job roles and hazards, and that you can pull records quickly if needed.

Include: Employee Name, Training Topic, Date(s) of Training, Trainer's Name, and Method of Training at a minimum.

4. Machine Guarding Issues

Unguarded or poorly guarded equipment shows up a lot, especially on older setups or equipment that’s been modified over time.

This is an issue that inspectors notice immediately. Put those guards on those hand grinders!

Fix: Walk your worksite with a critical eye. If there’s a moving part that could cause injury, it needs proper guarding.

5. PPE Isn’t Being Used Consistently

PPE is on-site but not always being used, or it’s being used incorrectly.

This usually comes down to enforcement, not availability.

Fix: Make expectations clear, train on proper use, and actually enforce it day-to-day.

None of these are complicated issues.

How to Get Ahead of It

• Ensure that the safety manual reflects current operational practices.
• Maintain consistency in inspections and retain appropriate records.
• Track training in a manner that allows for verification.
• Evaluate the site from an inspector's perspective and address any deficiencies.