OSHA Compliance
Emergency Action Plan Template — OSHA 29 CFR 1910.38
A free emergency action plan (EAP) template for manufacturers. Required for any employer with 10 or more employees under OSHA 29 CFR 1910.38. Covers all required elements: evacuation routes, emergency contacts, critical operation shutdown, employee accounting, and rescue/medical duties — with a filled-in example from a precision machine shop.
Free Emergency Action Plan Template
Word document (.docx) — use immediately, no sign-up required
Download Blank TemplateWorked Example — ABC Precision Manufacturing
Download ExampleWhy the EAP Is Often the First Document OSHA Asks For
When an OSHA compliance officer arrives at your facility — whether for a routine inspection or following an incident — one of the first requests is often to see the Emergency Action Plan. It is a quick test of whether you have the foundational safety management infrastructure in place.
OSHA 29 CFR 1910.38 makes the EAP mandatory for any employer with 10 or more employees. The plan must be written (not just verbal), kept at the workplace, and available to employees for review. For manufacturers, the requirement is not just administrative — manufacturing environments have specific emergency scenarios that a generic plan does not address: chemical spills, confined space rescue, crane loads, and equipment mid-cycle at the time of an evacuation order.
An EAP that actually works in a manufacturing environment requires thinking through these scenarios in advance — not during the emergency itself.
What OSHA 1910.38 Requires
Written Plan for 10+ Employees
The plan must be in writing, kept at the workplace, and available to employees for review. Smaller employers (fewer than 10) may communicate the plan orally, but OSHA recommends a written plan for any employer. The plan is not a one-size-fits-all template — it must reflect your specific facility, hazards, and layout.
Six Required Elements
OSHA 1910.38(c) specifies six required elements: (1) emergency reporting procedures, (2) evacuation procedures and exit route assignments, (3) critical operations procedures, (4) employee accounting, (5) rescue and medical duties, and (6) name of EAP contact. All six must be present for the plan to be compliant.
Employee Training
OSHA 1910.38(e) requires training when the plan is first developed, for new employees, and when the plan changes. A sufficient number of employees must be trained to assist in orderly evacuation. Annual drills are best practice, and training records must be retained.
What Your Emergency Action Plan Should Cover
Emergency Reporting Procedures
How employees report fires, chemical spills, medical emergencies, and other events. Include the primary method (pull station, verbal alarm, phone), backup methods, and the phone numbers for emergency services, the safety coordinator, and facility management. Specify who has authority to call 911 — in some facilities, this is anyone; in others, calls are routed through a designated person to avoid duplicate calls and coordinate with security.
Evacuation Routes and Exit Assignments
Identify all emergency exits and the primary and secondary evacuation routes from each area of the facility. Post evacuation route maps at every exit and work area. For manufacturing facilities, this includes exits from each production cell, back-of-house corridors, and any mezzanine or upper levels. Ensure routes are wide enough for all employees including those with mobility limitations, and that they are kept clear at all times.
Critical Operations — Who Stays and What They Do
Some operations cannot be immediately abandoned — a CNC machine mid-cycle, a chemical reactor in process, or a crane with a suspended load. Identify which operations require an orderly shutdown before evacuation, who is responsible for performing the shutdown, and the maximum time allowed before that employee must also evacuate. This section must be specific: "operator initiates E-stop on all CNC machines in Cell 1 before exiting via Exit B."
Employee Accounting After Evacuation
Define the assembly point(s) for each area of the facility, who is responsible for taking attendance at each point, and the method (headcount, sign-in sheet, badge scan). Specify what happens if someone is not accounted for — who contacts emergency services, who conducts the last-known-location check, who has authority to authorize a re-entry search. Accounting failures during evacuations have led to preventable fatalities when missing employees were later found still inside.
Rescue and Medical Duties
Identify employees trained and designated for rescue or medical response — first aid responders, AED-trained personnel, or those responsible for assisting employees with disabilities during evacuation. Specify who these employees are by name or role, what their duties are, and what equipment they use. Only employees with specific training may perform rescue duties — untrained rescue attempts frequently result in additional injuries.
Contact Information and Plan Custodian
OSHA requires the EAP to name the employee(s) who can be contacted by other employees for more information about the plan or their duties under it. Include the safety coordinator, facility manager, and after-hours emergency contacts. The plan must be kept at the workplace and made available to employees for review on request.
Training and Drill Schedule
Document when employees will be trained on the EAP, who will conduct the training, and when drills will be held. Annual evacuation drills are widely considered best practice. After each drill, debrief: how long did the evacuation take, were all employees accounted for, what problems were encountered? Use the debrief findings to update the plan. Retain training and drill records — OSHA inspectors may request them.
Filled-In Example: ABC Precision Manufacturing
Below is a key excerpt from the Emergency Action Plan at ABC Precision Manufacturing — a 28-employee CNC machine shop in a single-story 18,000 sq ft building. This shows the evacuation routing, critical operations, and employee accounting sections.
EMERGENCY ACTION PLAN — EAP-001
ABC Precision Manufacturing, LLC | Rev C | Effective: January 1, 2026
Plan Custodian: Robert Haines, Facility Manager | Next Review: January 2027
Emergency Contacts
| Role | Name | Primary | After Hours |
|---|---|---|---|
| Fire / Medical / Police | 911 | 911 | 911 |
| Safety Coordinator | Maria Gonzalez | (555) 401-2233 | (555) 401-2234 |
| Facility Manager (EAP Contact) | Robert Haines | (555) 401-2200 | (555) 401-2201 |
| Chemical Spill Response | CHEMTREC | 1-800-424-9300 | 1-800-424-9300 |
| Building Owner/Property Mgmt | Mesa Industrial Properties | (555) 872-4000 | (555) 872-4001 |
Evacuation Routes by Area
| Area | Primary Exit | Secondary Exit | Assembly Point | Warden |
|---|---|---|---|---|
| CNC Cell 1 & 2 | Exit B (North wall) | Exit A (Main entrance) | Parking lot — north end, yellow marker | D. Kim |
| CNC Cell 3 & Grinding | Exit C (East wall) | Exit B (North wall) | Parking lot — east side, yellow marker | J. Torres |
| Inspection / CMM Lab | Exit A (Main entrance) | Exit D (South side) | Parking lot — main entrance, yellow marker | Maria Gonzalez |
| Receiving / Shipping Dock | Exit E (Dock door — manual release) | Exit D (South side) | Parking lot — south end, yellow marker | James Park |
| Office | Main entrance | Exit D (South side) | Parking lot — main entrance, yellow marker | R. Haines |
Critical Operations — Orderly Shutdown Before Evacuation
| Equipment / Operation | Shutdown Action | Responsible | Max Time Allowed |
|---|---|---|---|
| CNC machines — mid-cycle | Press E-stop on each machine in assigned cell. Do not wait for cycle completion. | Cell operator (each cell) | 30 seconds max |
| Overhead crane — load suspended | Lower load to floor using pendant. If impossible, engage hoist brake and leave. | Crane operator | 60 seconds max |
| Natural gas supply | Do NOT shut off at panel — leave for fire department unless trained to do so. | Do not act | N/A |
| Coolant systems | Leave running — automatic shutdown via E-stop. | N/A | N/A |
All employees: if an operation cannot be safely shut down within the maximum time, leave immediately without completing the shutdown. No process is worth an injury.
Drill & Training Record (most recent)
| Date | Type | Duration | All Accounted? | Issues Found | Corrective Action |
|---|---|---|---|---|---|
| Jan 14, 2026 | Fire evacuation drill | 4 min 20 sec | Yes — 28/28 | Exit C door slow to open (stiff push bar) | Push bar lubricated and tested Jan 15. Re-drill not required. |
Keep EAP Training Current in Training Tiger
Every time your EAP changes — new emergency contacts, updated evacuation routes, new wardens — OSHA requires retraining. Training Tiger stores the EAP as a controlled document and automatically flags affected employees for retraining the moment a new revision is published. No one falls through the cracks.
- →Store the EAP as a controlled document — version history, approval workflow, effective date
- →Assign EAP training to all employees — track acknowledgment and sign-off per person
- →Automatic retraining trigger when the EAP is revised (new contacts, routes, or procedures)
- →Exportable training records for OSHA inspection — who was trained, when, on which version
Frequently Asked Questions
Is an Emergency Action Plan required by OSHA?
Yes. OSHA 29 CFR 1910.38 requires employers with 10 or more employees to have a written Emergency Action Plan. Employers with fewer than 10 employees may communicate the plan orally, but a written plan is strongly recommended for any organization.
What must an Emergency Action Plan include under OSHA 1910.38?
The EAP must include: (1) procedures for reporting emergencies, (2) evacuation procedures and exit route assignments, (3) procedures for employees remaining to complete critical operations before evacuating, (4) procedures to account for all employees after evacuation, (5) procedures for employees performing rescue or medical duties, and (6) the name or job title of the contact for more information about the plan.
How often must employees be trained on the Emergency Action Plan?
OSHA requires training when the EAP is first developed, for all new employees, and whenever the plan changes. OSHA does not specify a minimum frequency, but annual drills are best practice and may be required by state and local fire codes. Maintain records showing who was trained and when.
What is the difference between an Emergency Action Plan and a Fire Prevention Plan?
An EAP (OSHA 1910.38) covers all emergency types — fire, chemical spill, natural disaster — and focuses on safe evacuation or shelter-in-place. A Fire Prevention Plan (OSHA 1910.39) focuses on preventing fires: managing ignition sources and fuel loads, maintaining fire protection equipment. The two plans are often combined into a single document.