OSHA Compliance
OSHA Self-Inspection Checklist for Manufacturers — Free Download
A free OSHA self-inspection checklist covering the 10 areas most frequently cited in manufacturing facilities. Use it to find and fix compliance gaps before OSHA does — with a filled-in example showing how ABC Precision documents their quarterly inspections.
Free OSHA Self-Inspection Checklist
Word document (.docx) — use immediately, no sign-up required
Download Blank ChecklistWorked Example — ABC Precision Manufacturing
Download ExampleFind Violations Before OSHA Does
An OSHA inspection is not something manufacturers can fully prepare for in advance — OSHA can arrive unannounced for a programmed inspection, in response to a referral, or following an employee complaint. The best preparation is a facility that is already in compliance because gaps have been identified and corrected through regular self-inspections.
A self-inspection using this checklist serves two purposes: it identifies violations before they result in citations and penalties, and it demonstrates to OSHA (if they do arrive) that your organization has an active, good-faith safety program. OSHA can reduce penalties by up to 25% for employers who have an effective safety program, and self-inspection records are evidence of that program.
This checklist focuses on the 10 areas most frequently cited in general industry manufacturing, based on OSHA's published top violations data. It is not a substitute for a comprehensive compliance review, but it covers the areas most likely to generate citations in a typical machine shop or light manufacturing environment.
What the Checklist Covers — 10 Inspection Areas
Below is a condensed preview of the checklist. The full downloadable version includes all items with pass/fail/N A checkboxes, a findings column, corrective action fields with responsible person and due date, and an inspection certification section.
Hazard Communication (HazCom) — 1910.1200
- Written HazCom program is documented, current, and available to employees
- Chemical inventory (SDS index) lists all hazardous chemicals in the facility
- Safety Data Sheets are available for every chemical — accessible to employees during all shifts
- All containers of hazardous chemicals are properly labeled (product name, hazard pictograms, signal word)
- Employees have been trained on HazCom: hazards present, how to read an SDS, label elements
- Training records are on file and current for all exposed employees
Lockout/Tagout — 1910.147
- Written energy control program exists and is accessible
- Machine-specific LOTO procedures exist for each piece of equipment where employees perform service/maintenance
- LOTO procedures are posted at or near each machine
- Each authorized employee has a personal padlock — locks are labeled with the employee's name
- Lockout hardware (hasps, valve lockouts, clamps) is in good condition and accessible at each work cell
- Annual LOTO procedure inspections are documented with written certifications
- Training records on file for authorized employees, affected employees, and other employees
Machine Guarding — 1910.212
- All point-of-operation hazards on machines are guarded
- Guards are secure and cannot be easily removed without tools
- No machines operating with guards removed or bypassed
- Rotating parts (shafts, couplings, sprockets, pulleys) are guarded
- Ingoing nip points are guarded
- Flying chips, sparks, or coolant are controlled by guards or barriers
- Machine operators are trained on the purpose of guards and not to bypass them
Powered Industrial Trucks (Forklifts) — 1910.178
- All forklift operators are trained and certified — records on file
- Operators are evaluated at least every 3 years
- Daily pre-shift inspections are completed and documented
- Damaged or defective forklifts are tagged out and removed from service
- Forklift speed limits and pedestrian separation are enforced
- Forklifts are not used to lift personnel (without an approved work platform)
- Charging areas are properly ventilated
Eye & Face Protection — 1910.133
- PPE hazard assessment (written and certified) is on file — identifies all areas/tasks requiring eye protection
- Appropriate eye/face protection is available and used in all identified areas
- Safety glasses meet ANSI Z87.1 — check for Z87 marking on frame/lens
- Face shields are used over safety glasses for grinding, molten material, and chemical splash
- PPE is inspected regularly — scratched or damaged lenses are replaced
- PPE training records are on file for all employees required to use eye/face protection
Electrical Safety — 1910.303 / 1910.305
- All electrical panels are accessible — no storage within 36" of panel faces
- All panel knockouts are filled — no open knockouts
- Electrical cords are in good condition — no damaged insulation, splices, or improper repairs
- Extension cords are not used as permanent wiring
- GFCI protection is provided for all outlets in wet or damp locations
- All junction boxes, outlet boxes, and conduit fittings have proper covers
- Electrical equipment near flammable materials meets applicable requirements
Walking/Working Surfaces & Housekeeping — 1910.22
- All aisles and passageways are kept clear and in good repair
- Floors are clean, dry, and free of slip/trip hazards
- Drainage is adequate in wet process areas; anti-slip matting is present where needed
- Permanent aisles are marked (painted lines, floor tape, or equivalent)
- No materials stored in aisles, walkways, stairways, or in front of emergency exits
- Exits are clearly marked and unobstructed at all times
- Lighting is adequate in all work areas, aisles, and stairways
Emergency Exits & Fire Prevention — 1910.37 / 1910.39
- All emergency exits are clearly marked with illuminated "EXIT" signs
- Emergency exit signs are functional — test monthly
- Emergency lighting is functional — test monthly
- Exit routes are unobstructed and of sufficient width
- Fire extinguishers are mounted, visible, and accessible — not blocked
- Fire extinguishers are inspected monthly (tag current) and annually by a licensed service
- Flammable and combustible materials are properly stored
- Smoking is prohibited in areas where flammable/combustible materials are stored or used
PPE — General (1910.132) & Hearing (1910.95)
- Written PPE hazard assessment is completed, certified, and current
- Required PPE is provided, maintained, and replaced when damaged
- Hearing protection is provided and used in all areas where noise exposure ≥ 85 dBA
- Noise levels have been measured or conservatively estimated in high-noise areas
- Hearing conservation program is in place if any employee exposures reach 85 dBA TWA
- Hard hats are worn in overhead hazard areas and near heavy equipment
- High-visibility vests are worn in active forklift traffic areas
Training Records & Written Programs
- Emergency Action Plan exists, is written, and is accessible to all employees
- All required OSHA written programs are on file: HazCom, LOTO, PPE Assessment, EAP
- Training records are maintained for all required OSHA training topics
- Records show who was trained, when, on what topic, and by whom
- New employee safety orientation is documented
- Retraining is documented when required (procedure changes, equipment changes, incidents)
- OSHA 300 log is current for the calendar year
How to Use This Checklist
Schedule a Dedicated Walk-Through
Block 2–4 hours to walk the entire facility with the checklist. Do not complete it from a desk — each item requires physical verification. Bring a camera.
Mark Each Item Pass, Fail, or N/A
Be honest. Items marked "fail" are opportunities to fix something before OSHA finds it. Document the specific finding, not just "fail" — "fire extinguisher in CNC Cell 1 inspection tag expired March 2026" is more actionable than "extinguisher issue."
Assign Corrective Actions Immediately
For each failed item, assign a responsible person and a completion date before you finish the walk-through. High-hazard findings (blocked exits, bypassed machine guards) should be corrected same day.
Certify and Retain the Completed Checklist
Sign and date the completed checklist. Retain it as a safety record. If OSHA arrives, a documented history of self-inspections and corrective actions demonstrates your good-faith safety program.
Follow Up on Open Items
Set a calendar reminder to verify all corrective actions were completed. Document the completion date on the checklist. An inspection with open, unaddressed findings is worse than no inspection at all.
Keep Safety Training Records Audit-Ready in Training Tiger
The training records section of this checklist is the most common area where manufacturers fall short — not because training didn't happen, but because records were not kept. Training Tiger stores every training record with a timestamp and employee sign-off, so when OSHA asks to see HazCom training records from 2 years ago, you can produce them in minutes.
Frequently Asked Questions
Does OSHA require employers to conduct self-inspections?
OSHA does not mandate formal self-inspections on a set schedule, but the General Duty Clause requires employers to provide a workplace free from recognized hazards. Regular self-inspections are the most practical way to satisfy that obligation proactively. OSHA's own Recommended Practices for Safety and Health Programs explicitly encourages systematic workplace inspections as a core element.
What are the most commonly cited OSHA violations in manufacturing?
For general industry manufacturing: hazard communication (1910.1200), lockout/tagout (1910.147), machine guarding (1910.212), powered industrial trucks (1910.178), PPE — eye and face (1910.133), and electrical wiring methods (1910.305) are consistently in OSHA's top 10. This checklist covers all of them.
How often should a manufacturing facility conduct a self-inspection?
At minimum, a comprehensive annual inspection using a checklist like this one, supplemented by informal supervisor walk-arounds weekly. High-hazard areas benefit from quarterly targeted inspections. After any incident or near-miss, inspect the relevant area immediately. Some state OSHA programs and insurance carriers require specific inspection frequencies.