1. Most Frequently Cited Serious
OSHA Standards – General Industry
FY 2012
OSHA Safety Day , March 12, 2013OSHA Safety Day , March 12, 2013
Sauk Valley Community CollegeSauk Valley Community College

2. #1 1910.1200(e)(1)
• Need written hazard
communication
program (your local
OSHA office can
provide you with a
sample electronic
program)
• Must contain a list of
hazardous chemicals,
MSDS (SDS) labels,
employee info &
training.
First trigger date under
Revised haz com standard is
December 1, 2013 – must train
employees on new label elements
And SDS format.

3. #1 1910.1200(e)(1)
• No training of
employees in the
hazards of chemicals
• Signs and symptoms
of exposure
• Emergency response
(visual, odors)
• Physical & health
hazards

4. #1 1910.1200(e)(1)
When is a haz
haz com really
serious???

5. #1 1910.1200(e)(1)
• Methanol-containing
washer fluid. Label
reads: “Cutting,
welding or grinding
on containers
might cause fire,
explosion or
release of harmful
fumes.”

6. #1 1910.1200(e)(1)
• Improper mixing of
cleaning chemicals
may cause chlorine and
ammonia gas release.
• Exposure can cause
eye and respiratory
tract irritation,
dizziness, cough, chest
pain, pulmonary
edema, lung injury,
pneumonia, asthma-
like symptoms, etc.

7. #2 1910.147(c)(4)
.147(c)(4)(i)
Procedures shall
be developed,
documented &
utilized for the
control of
potentially
hazardous energy
when employees
are engaged in the
activities covered
by this section.

8. #2 1910.147(c)(4)
• Lockout/tagout
procedures are not
just for maintenance
employees!
• Machine operators
who clear jams,
make adjustments
and clean machine
parts may need to
lock out also.

9. #2 1910.147(c)(4)
• .
Typical lockout observed.

10. #2 1910.l47(c)(4)
Less typical lockout observed. This lockout device is a
mechanical pin, inserted beneath a stacker to prevent a
gravity hazard while employees are beneath the stacker.

11. #2 1910.147(c)(4)
Mechanical pin that locks out gravity hazard.

12. #3 1910.178(l)
• The employer shall
ensure that each
powered industrial truck
operator is competent to
operate a powered
industrial truck safely, as
demonstrated by the
successful completion of
the training and
evaluation specified in
this paragraph (l).

13. #3 1910.178(l)
Training includes a variety of vehicles such
as order pickers and motorized pallet jacks.

14. #4 1910.212 (a)(1)
• One or more methods of machine
guarding shall be provided to protect the
operator and other employees in the
machine area from hazards such as those
created by point of operation, ingoing
nip points, rotating parts, flying chips
and sparks. Examples of guarding
methods are barrier guards, two-hand
tripping devices, electronic safety devices,
etc.

15. #4 1910.212 (a)(1)
• Lathes
• Need a chip guard for
many operations
• When jaws extend
past chuck, a guard
would be needed.

16. #4 1910.212 (a)(1)
• Injection Molding
Machine
• Most have
interlocked gate as
a guarding means.
• What other safety
devices might this
machine have?

17. #4 1910.212 (a)(1)
• Tube Benders
• 2-hand controls are
effective
• Pressure mats can be
used to avoid the
tubes that are being
bent.

18. #4 1910.212 (a)(1)
• Printing presses
• They must be
guarded at the
in-running nip
points of the rollers.

19. #4 1910.212(a)(1)
• Employer installed
electric eye beam
across length of
ingoing nip point
(between rollers) on
this conveyor line.
• Electric eyes are
tested at beginning of
shift to be sure
machine stops when
beam broken.

20. #8 1910.212(a)(1)
Large rollers at end of plastics
de-baling machine conveyor.
Employees protected by fall
restraints not allowing
them to get closer than 3 feet.
Diagram of employee caught in
ingoing nip point between large
rollers.

21. #4 1910.212(a)(1)
Employee’s hand slipped into unguarded portion of blade.

22. #4 1910.212(a)(1)
Employer obtained retrofit guard kit from manufacturer.

23. #4 1910.212(a)(i)
• Shears
• Guards must prevent
entry to cutting blade.
• This shear has had its
“finger” guards bent
back in violation.
• The guard must also
prevent access to
the hold-downs,

24. #4 1910 .212(a)(i)
Foot pedal-operated iron worker needs
point of operation guarding. Options
include barrier guard, 2-hand controls,
restraints, restrict POO opening to ¼”

25. #4 1910.212(a)(i)
• Vertical Bandsaw
• Adjustable guard to
height of product
• Many injuries by
guiding product into
POO
• Handling cold slippery
products, such as in
food processing, will
increase chances of
slipping into POO

26. #4 1910.212(a)(i)
• Radial Arm Saws
cutting metal
• Lower blade
awareness device
• Retracts to original
position
• Does not extend past
plane of table
• Anti-kick back device

27. #4 1910.212(a)(i)
• Shears
• Guards must prevent
entry to cutting blade.
• This shear has had its
“finger” guards bent
back in violation.
• The guard must also
prevent access to
the hold-downs,

28. #5 1910.134(e)(1)
• The employer shall
provide a medical
evaluation to determine
the employee’s ability to
use a respirator, before
the employee is fit tested
or required to use the
respirator in the
workplace.

29. #6 1910.305(g)(1)
(iv)… Flexible cords & cables may not be:
A)Used as a substitute for fixed wiring of a structure
B)Run through holes in walls, ceilings or floors
C)Run through doorways, windows or similar openings;
D)Attached to building surfaces
E)Concealed behind bldg. walls, ceilings , floors
F)Installed in raceways (unless otherwise permitted)

30. #6 1910.305(g)(1)
Damaged flexible cords from misuse expose
employees to electrical shock and fire hazards.

31. #6 1910.305(g)(1)
Extension cord run up wall, across
ceiling and down opposite wall to
power a pump.

32. #6 1910.305(g)(1)
• Hazard: Flexible
cord is run
through hole in
the wall from one
room to another
inside the plant.

33. #7 1910.303(b)(2)
• Installation and
use. Listed or
labeled equipment
shall be used or
installed in
accordance with
any instructions
included in the
listing or labeling.
A relocatable power tap (RPT) is
used in an industrial setting, not in
accordance with listing/labeling
instructions.

34. #7 1910.303(b)(2)
Knockout style box use on flexible cord created shock hazard.
Equipment not used per directions in listing and labeling.

35. #7 1910.303(b)(2)
One method of abatement is to
mount the knockout style boxes and
use with conduit.

36. #8 1910.219(d)(1)
• Pulleys, any parts of
which are seven (7)
feet or less from the
floor or working
platform, shall be
guarded in
accordance with the
standards specified in
paragraphs (m) and
(o) of this section.
Ingoing Nip Point

37. #4 1910.219 (d)(1)
• The in running nip of
the roller fabric and
the driver roller
(pulley) must be
guarded.
• This conveyor is well
guarded.

38. #8 1910.219(d)(1)
MSHA Fatality – Employee caught in unguarded
pulley when standing on work platform.

39. #9 1910.132(d)(1)
• The employer shall
assess the workplace
to determine if
hazards are present,
or likely to be
present, which
necessitate the use
of personal protective
equipment (PPE)

40. #9 1910.132(d)(1)
This employer’s PPE hazard assessment determined
that all employees cutting fish would wear a metal mesh
glove on the hand opposite the hand holding the knife.

41. #10 1910.23(c)(1)
• Protection of open-side floors, platforms
and runways. Every oopen-sided floor or
platform 4 feet or more above adjacent
floor or ground level shall be guarded by a
standard railing (or the equivalent per
para. (e)(3)on all open sides excpet when
there is entrance to a ramp, stairway, or
fixed ladder.

42. #10 1910.23(c)(1)
Employee exposed to fall while standing on
top of machine.

43. #10 1910.23(c)(1)
Employee exposed to fall on top of tanker truck – he was
OK until he stepped off the ladder.

44. #10 1910.23(c)(1)
Personal Fall Arrest System
(PFAS) anchorage point (5,000
lbs) and retractable lanyard
installed in milk depot for
employees needing to access top
of tanker trucks.
A PFAS can usually be used
in lieu of guardrails when
guardrails are not feasible
or practical.

45. Resources
• OSHA website: www.osha.gov
• State of Illinois Onsite Consultation Service
– www.illinoisosha.com (312) 814-2337
USDOL-OSHA Aurora Area Office: 630-896-8700

46. Disclaimer Language
This information has been developed by an OSHA Compliance Officer and is
intended to assist employers, workers, and others as they strive to improve
workplace health and safety. While we attempt to thoroughly address specific
topics (or hazards), it is not possible to include discussion of everything
necessary to ensure a healthy and safe working environment in a presentation
of this nature. Thus, this information must be understood as a tool for
addressing workplace hazards, rather than an exhaustive statement of an
employer’s legal obligations, which are defined by statute, regulations, and
standards. Likewise, to the extent that this information references practices or
procedures that may enhance health or safety, but which are not required by a
statute, regulation, or standard, it cannot, and does not, create additional legal
obligations. Finally, over time, OSHA may modify rules and interpretations in
light of new technology, information, or circumstances; to keep apprised of such
developments, or to review information on a wide range of occupational safety
and health topics, you can visit OSHA’s website at www.osha.gov.