OSHA inspectors cited warehouses and manufacturing facilities for the same clusters of violations last year that they cited the year before. The violations are predictable — which means they're preventable. This checklist covers the most frequently cited standards so your EHS team can audit proactively instead of waiting for an inspector to find your gaps.
Use this as a starting point for your internal audit program, not a substitute for it. OSHA standards are detailed, and this checklist covers the high-level requirements. For each item, your facility should maintain documented evidence of compliance: written programs, training records, inspection logs, and corrective action history.
1. Hazard Communication (HazCom) — 29 CFR 1910.1200
- Written hazard communication program is current, accessible, and facility-specific
- Safety Data Sheets (SDS) are available for every hazardous chemical on-site and organized for immediate access
- All containers are properly labeled with product identifier, hazard pictograms, signal word, and supplier contact information
- All workers who work with or near hazardous chemicals have completed HazCom training and records are documented
- New chemical introductions trigger SDS review and updated labeling before use begins
2. Lockout/Tagout (LOTO) — 29 CFR 1910.147
- Written energy control program exists and covers all energy sources: electrical, hydraulic, pneumatic, thermal, chemical, and gravitational
- Machine-specific lockout procedures are posted at each piece of equipment requiring LOTO
- Annual LOTO procedure reviews are completed and documented for each machine
- All authorized and affected employees have received LOTO training; retraining records are current
- LOTO hardware (locks, hasps, tags) is available at each energy isolation point and is exclusively used for LOTO — not general security
3. Powered Industrial Trucks (Forklifts) — 29 CFR 1910.178
- All forklift operators hold current operator certification with documented training and evaluation records
- Daily pre-operation inspection checklists are completed and retained for each truck
- Refresher training is triggered after observed unsafe operations, near-misses, or workplace condition changes
- Travel aisles maintain required clearances and are clearly marked; pedestrian and vehicle traffic is separated where possible
- Maximum load capacity plates are posted on every truck and loads are never exceeded
4. Walking-Working Surfaces — 29 CFR 1910.22 and 1910.23
- All floors, aisles, and stairways are kept clean, dry, and free of obstructions; housekeeping inspection logs are maintained
- Floor openings, holes, and elevated work surfaces have proper guarding or covers rated for the expected load
- Fixed ladders meet angle, rung spacing, and extension requirements; side rails extend at least 42 inches above landing
- Loading dock edges are guarded or marked; fall hazards in receiving areas are assessed and controlled
- Mezzanines and elevated storage platforms have standard guardrails: 42-inch top rail, mid-rail, and toe board
5. Emergency Action Plans — 29 CFR 1910.38
- Written emergency action plan (EAP) exists and covers fire, chemical release, medical emergency, and severe weather at minimum
- EAP is reviewed with all employees upon initial assignment and whenever the plan changes
- Emergency escape routes are posted, clearly marked, and kept unobstructed at all times
- Alarm systems are tested at required intervals; fire drills are conducted and documented annually
- Designated assembly points are established and communicated to all employees and contractors
6. Recordkeeping — 29 CFR 1904
- OSHA 300 Log is maintained for the current year and the previous five years; all recordable incidents are entered within 7 calendar days of learning of the case
- OSHA 300A Summary is posted in a conspicuous location from February 1 through April 30 each year
- OSHA 301 Incident Reports or equivalent are completed for every entry on the 300 Log
- Fatalities are reported to OSHA within 8 hours; in-patient hospitalizations, amputations, and eye losses are reported within 24 hours
- Facilities with 20+ employees submit 300A data electronically via OSHA's Injury Tracking Application annually
7. Personal Protective Equipment — 29 CFR 1910.132
- Written PPE hazard assessment is on file, signed by a certifying official, and covers all job classifications
- PPE is selected based on assessed hazards, not convenience; selection documentation is maintained
- Employees receive training on which PPE to use, when to use it, how to put it on and remove it, and how to inspect and maintain it
- Defective or damaged PPE is immediately removed from service; replacement inventory is adequate
- PPE use is enforced in designated areas and during designated tasks; enforcement records are maintained
Turning a Checklist into a Living Compliance Program
A checklist is a point-in-time snapshot. OSHA compliance requires continuous monitoring. Every item on this list can drift out of compliance between audits — a new chemical arrives without an SDS, a forklift certification expires, a guardrail gets damaged and isn't replaced. The gap between your last audit and your next one is where violations develop.
Safety management platforms like Mantid address this by giving EHS managers real-time visibility into compliance status across all sites. Inspection findings feed directly into corrective action workflows. Training due dates trigger automated reminders. Compliance dashboards show open gaps at a glance — so your team can fix issues before they become citations.
The best OSHA compliance program isn't the one with the most paperwork — it's the one that catches gaps in real time and closes them before an inspector does.