Facility Safety Audit Guide (Fsa)

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Facility Safety
Audit Guide
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CONTENTS
At Graphic Products® we are serious about facility safety. So we developed this comprehensive audit guide based on our 40+
years of industry experience. Our DuraLabel line of thermal transfer printers has become the global industry standard for facility
safety labeling. Paired with our 50 specialty supplies, you can communicate your message under any conditions and in any
environment.
Call us at 877.534.5157 for free support as well as advice on making sure your facility is up to code with visual communication
requirements to protect your employees.
INTRODUCTION............................................................................................. pg 1
Inspection or Audit—What’s the Difference?
Workplace Injuries in 2015
DEVELOPING AN INSPECTION & AUDIT PROGRAM.......................... pg 2

Who Should the Inspectors/Auditors Be?
Conducting a Safety Inspection
Conducting a Safety Audit
Prioritize Your Findings
Document & Store Your Audit Results
4 Do you have proper PPE practices in place at Visual Communication Inspection

pg your facility?
PREPARING FOR AN OSHA INSPECTION............................................ pg 12
Workplace Inspections
Exemptions
Getting Your Company Ready
Top 10 OSHA Violations for 2016
When the Compliance Officer Knocks
The Four Parts of an OSHA Inspection
SIGNS & LABELS FOR YOUR FACILITY............................................... pg 19

OSHA’s General Duty Clause
The Four C’s of Labeling
pg 2O Are you using the best material for your

sign/labeling job?
What Material is Right for Your Job?
Sign & Label Inspection Guidelines
APPENDIX A: THE TOP 6 SAFETY SIGNS & LABELS...................... pg 22
APPENDIX B: SAMPLE FACILITY SAFETY INSPECTION

CHECKLIST................................................................................................... pg 25
Content may have been updated to reflect the latest codes,

standards, and regulations or to address any errors or omissions.
For the most up to date edition, visit: GraphicProducts.com/guides
This document contains information derived from sources we deem reliable. Graphic Products, Inc. has made reasonable efforts to ensure correctness but
does not guarantee accuracy or completeness. Graphic Products makes no warranties express or implied regarding the contained subject matter. Contents are
subject to change without notice. Graphic Products disclaims liability for injury, damage, or loss arising from reliance on the information contained herein. Users
of this information should independently consult municipal, state, or federal code and/or verify information with the appropriate regulatory agency.
INTRODUCTION
OSHA requires employers to provide a safe workplace, but being committed to safety can also decrease insurance costs,
increase productivity, and improve worker morale. By following OSHA’s compliance standards, providing proper training, and
being vigilant about identifiable hazards, employers can reduce injuries and even fatalities. Two powerful tools at the disposal
of industrial facility and safety managers are the facility safety inspection and the safety audit. When successfully implemented,
these tools can help keep your workforce safe.
Inspection or Audit—What’s the Difference? With an inspection and audit program, backed by
improved practices and enforcement, your results
Inspections will be:
Industrial facility safety inspections focus on compliance • Decreased workplace injuries and fewer loss days for
standards pertaining to the physical environment: emergency employees (Unsafe situations and work practices can
exits, fire extinguishers, machine guards, hazardous material be eliminated.)
storage, etc. In addition to visual observation and discussing • Improved workers comp premiums (Reducing injuries
hazards with employees, a detailed checklist is used to over time improves your company’s insurance risk and
assess the facility’s safety readiness across several criteria. lowers rates.)
Think of an inspection as “preventive maintenance” for • An increase in employee morale and productivity (When
facility safety, where the goal is not to discover how many workers know that management values them, morale
problems there are but rather identify adjustments needed to and productivity rise.)
improve operations and strengthen existing procedures.
• Greater efficiency (Damaged or malfunctioning
machines are taken offline until repaired; workflow
Audits
frequently improves.)
Industrial facility safety audits, on the other hand, focus
• Improved standing when bidding on jobs (In the
on work processes. Individual job functions are compared
construction industry, a deciding factor in comparing
against best practices to find potential safety breakdowns. As
bids can be the bidder’s workers’ comp experience
a result of a safety audit, job functions may warrant greater
modification rating.)
enforcement of best practices or they may be modified to
eliminate potentially hazardous behaviors or conditions. A • Decreased likelihood of litigation (Fewer injuries mean
facility audit is often a diagnostic tool to discover the cause less exposure to lawsuits.)
of safety problems. Identifying areas to improve training not
only ensures you are in compliance but meets the larger goal
in mind; to prevent accidents, injuries, and save lives.
Workplace Injuries in 2O15

Nearly 3 million nonfatal workplace injuries
and illnesses were reported by private industry
employers.
Total recordable cases: 2,905,900
Cases involving days away from work: 902,200
Median days away from work: 9
Cases involving sprains, strains, tears: 331,180
Cases involving back injuries: 162,720
Cases involving slips, trips, and falls: 247,120
Source: BLS.gov
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DEVELOPING AN INSPECTION & AUDIT PROGRAM
Have you set the stage at work to take safety seriously? Do employees and management obey safety policies themselves?
Risk exposure exists in every company. Regardless of your company’s size and scope, it is proactive to develop an
audit or inspection program yourself—one that includes periodic assessments and tracks progress.
Considerations for an inspection and audit Effective programs thrive on

program include: consistency. When enacting a program,
adhere to your schedule and do not
• Who conducts the inspection or audit?
significantly delay any inspections
• What is the accountability structure for correcting the findings? and audits. Also, internal
• Will inspections and audits be unannounced or announced? enforcement regarding
corrective actions must be
• How often will a facility or operation be inspected or audited? evenly applied across all
• How can training be identified and reinforced during a levels and divisions within
self audit? the company.
Who Should the Inspectors/Auditors Be? location or industry, other credentials or qualifications
might be justifiable.
Inspectors and auditors usually consist of a team of
in-house safety experts. People that participate in the Specialized inspectors may be brought in to examine
company safety committee or outside consultants (such as machinery, such as boilers or the company’s fleet of
industrial hygienists or insurance company specialists) may vehicles.
be candidates. There must be sufficient expertise within
the team to know the right places to look and the right Many insurers have risk-management specialists who
questions to ask. There needs to be someone well-versed work with your safety manager or safety committee to
in compliance issues as well as state laws and regulations identify safety risks and recommend corrective action and
relating to your industry. education. Ask your workers’ comp insurer or insurance
broker for details.
Internal Resources
OSHA’s Consultation Program
Internal inspectors or auditors could be safety specialists
from within the company, a team of supervisors, OSHA’s Consultation Program is another inspection
representatives of the safety committee, or a combination service—completely free of cost and separate from its
of these resources. Safety experts agree that executive enforcement program—in which businesses can request
buy-in is essential; either a high-level manager should the service of an OSHA-approved consultant. The OSHA
participate, or everyone should understand that the findings consultant will do a complete safety assessment and
and recommendations are binding, or both. The effort must provide a written report summarizing findings as well as
include the most qualified people from within the company, resources available, such as education and other means
even though considerations such as scheduling and of support. Employers are expected to correct any serious,
frequency of assessments may be taken into account. unsafe, or unhealthful conditions within a reasonable
period of time.
Outside Resources Consultations through this program will not result in any
Your company may find it useful to work with an outside citations or penalties, although it is not guaranteed that
safety consultant. Contracting with a consultant may provide the employer will pass subsequent OSHA inspections that
the benefit of ongoing, intensive work to rectify safety and are part of the enforcement program.
health issues within the company. Credentials to look for
This program is available to any company with fewer than
include a Certified Safety Professional (CSP) or Certified
250 employees at a fixed site and no more than 500
Industrial Hygienist (CIH) designation. Depending upon your
corporate-wide.
877.534.5157 | GraphicProducts.com 2
Conducting a Safety Inspection Schedule your inspection so it does not impact periods of
high production. The inspection team should not interfere
As preventive maintenance for your facility’s safety record, with the work of the employees unless there is an imminent
a safety inspection can be conducted when it seems like threat to life or health. The team should always wear any
“everything’s OK” or when there has been an uptick in PPE appropriate to the work area. The best approach is to
injuries or near misses. If you choose to announce your hold the inspection in advance of a busy period in order to
inspection in advance, make sure all employees are aware of address any findings before activity increases, but don’t delay
the date and time as it may impact their schedule. the inspection just to be more efficient.
7 Tips for Safe & Effective Inspections
1. Prioritize your observations. If safety is your first concern, filter

your observations for that. Operational efficiency observations
can be noted as well, but reported separately unless they
directly impact safety too.
2. Observe with intention. Practice observing work areas and

processes and you will notice new things more often.
3. Be open-minded. Facts often defy our opinions.

Delay judgment until all facts are known.
4. Don’t trust first impressions. No matter how

clean the work environment is or how well
rules are adhered to, hazards may lurk.
5. Think like a journalist. A journalist

always asks who, what, where, when,
how, and why; so should a safety
inspector.
6. Don’t try to fix it right now. Resist the

urge for hazardous material handling,
heavy lifting, and other activities
designed to fix things on the spot. If any
chemical or environmental testing must be
conducted, enlist an expert for that purpose. If,
however, it’s an easy fix, workers may attend to it
immediately; just make a note of what occurred.
7. Work your checklist, but don’t let your checklist work you. Adhere to your
checklist and make sure every line item is answered. Focusing exclusively on your
checklist may give you “tunnel vision,” preventing you from noticing other issues in plain sight. Be sure you track your
results, making note of the date and recording any comments that may clarify what you observed or recommended.
High-impact Areas for Facility Safety Inspection Control of Hazardous Energy (Lockout/Tagout)
Most time-loss injuries (common in OSHA safety violations) There are many ways workers can be injured or worse
center on key aspects of industrial operations. To stay when hazardous energy in machines is not properly
safe and compliant, here are some of the main topics to controlled.
address in a safety inspection:
Employees must be made aware of the LO/TO procedures
and no duplication of padlock keys can be allowed.
Personal Protective Equipment
Failure to use personal protective gear is a leading cause For more information on lockout/tagout, contact Graphic
of serious injury in the workplace. Not only is it important to Products.
have the right gear in the right quantities, but consider the
following as well: Fall Protection
• Is the gear properly maintained and in good shape? Employees must be protected in general work areas from
• Is it available in sizes that are comfortable for all falling from overhead platforms or elevated work stations
employees to wear? or into holes whenever the fall distance is four feet or
more. For specific industries, OSHA requires fall protection
• Are the PPE storage locations at different elevated distances; five feet in shipyards, six
identified and marked to be feet in construction, and eight feet for maritime activities.
easily accessed by all? Ensure that your employees are properly protected and
• Is the gear inspected, replaced, always wear fall protection gear when at risk.
and cataloged regularly?
Electrical Safety
Machine Guarding Ensure wires are correctly stored and marked to increase
All industrial machinery must be examined for guarding efficiency and reduce fire hazards. Use our new Best
issues. Chains, belts, gears, conveyors, grinders, punches, Practice Guide to Wire and Cable Marking to eliminate a
and other machinery can easily cause major bodily harm crossed-wire mess. Installed electrical wiring represents
or death if not properly guarded. Safety experts observe a a hidden threat that can result in electrocution or fire.
hierarchy for reducing machine risk: Exposure to water or high heat can threaten the integrity of
electrical circuits, especially if they haven’t been wired to
1. Eliminate risk. Design or make modifications to reduce code. In addition, when high-voltage equipment is present,
unnecessary motion and exposure. an arc flash hazard may also be a serious risk. It may take
2. Install physical barriers. If design cannot minimize someone with in-depth understanding of electrical codes
hazard, install fixed guarding to provide a barrier to the and safety to accurately assess electrical risk. Lockout/
hazard, thus reducing exposure. tagout is also a key aspect of electrical safety.
3. Monitor access to the machine. If a physical barrier
is unfeasible, prevent unsafe conditions by monitoring Confined Spaces
access to the hazard. Confined spaces—enclosed areas large enough to work
4. Awareness and PPE. Practice awareness and use PPE in, but not designed for continuous occupancy and with
if exposure to unsafe conditions cannot be prevented. limited access—must be identified and labeled, and in
Proper HazCom 2012 or ANSI-compliant signage (Caution, many cases, certified. For more information on confined
Danger, Warning) prominently displayed plays a vital part spaces, contact Graphic Products.
in increasing risk awareness.
5. Training and procedures. Place administrative controls in
regard to procedures to minimize risk of injury, especially
if personnel cannot otherwise be protected from exposure Easily organize your wires and
and potential injury. cables using our Shrink-tubing
or Self-laminating Wire Wraps.
Third-party machine safety specialists are often experts in identifying

hazards related to industrial machinery. Consider hiring one.
Hazardous Materials (General) Emergency Preparedness

In accordance with HazCom 2012, all hazardous materials, All employees should know how to evacuate the building in
including solvents, fuels, batteries, cleaners, lubricants, and the event of an emergency, and evacuation routes should be
other potentially hazardous materials must have safety data clearly posted. Fire extinguishers should be inspected, up-to-
sheets (SDSs), formerly known as material safety data sheets date, and plainly visible to any employee. All doors, including
(MSDSs), by June 2015. Chemicals and other hazardous exits, must be clearly marked and unobstructed to allow
products, including contents in secondary containers, must immediate egress from the building.
be labeled and stored according to SDS information and
OSHA’s HazCom 2012 standard. Employees with hazardous
materials in their work areas must have received HazCom
2012 training regarding labeling of materials in 2013 and
onward. For more information on GHS and HazCom 2012 Special Considerations
labeling, contact Graphic Products.
Specialized Equipment & Procedures
Housekeeping & Storage Pressurized equipment, such as boilers,
Spills, slips, and obstructions occur when general autoclaves, digesters, and air receivers, as well
housekeeping is not kept up—or items are not stored as mechanical handling equipment such as
properly. Work practices and materials need to be in place to cranes, hoists, elevators, and chains, can be
prevent accidents. Make sure stairways and emergency exits extremely hazardous and require both engineering
are well marked and clear for traffic. Adequate procedures knowledge and specialized training to test
must be in place to address any spills on floors, along with effectively. At least two members of the inspection
access and storage of items used to contain and clean. team should have this expertise.
Organization throughout your facility is critical to efficiency
and minimizing injury. Overhead Inspections
Objects may fall from building structures,
Lighting roofs, cranes, rigging, and suspended fixtures.
Both interior and exterior lighting must function to keep Conducting an overhead inspection may reveal
employee work areas and walkways safe at all times. Ensure the need for repairs that, when you don’t look up,
that all signs and labels are prominently visible in appropriate are easy to miss. Deadly combustible dust can
work lighting and conditions. accumulate on overhead structures, and also
above ceiling tiles and in duct areas. Create a
Ladders regular cleaning schedule of air-ducts to prevent
illness.
Ladders must be the appropriate length for their associated
tasks. Only non-metallic ladders can be used if electrical
Taking Equipment
contact is even a remote possibility. Unsafe ladders must
Offline
be tagged for removal, and employees using ladders must
be trained in their safety. Ladders must be stored properly, If a tool or piece of
away from heat, moisture, and sunlight. Non-self-supporting machinery is unsafe,
ladders must be stored on flat racks or wall brackets that it must be taken
prevent sagging. Stepladders must be stored vertically and offline immediately.
closed. Be sure to follow
proper lockout/
tagout procedures,
Medical/First Aid
and keep it locked
First-aid kits must be easily accessible for employees. OSHA out until it is
advises that large facilities should have defibrillators, and operating safely.
where chemicals are a risk, eye-washing stations must be
clean, functioning, and clog‑free.
Conducting a Safety Audit OSHA suggests that for every task, use the following
questions to analyze the hazards that task may present:
Before you begin your safety audit, it’s a good idea to assess
your facility’s needs. Has there been an increased rate of
injury in your facility? Is it localized in one or two departments Question Example of answer
or operations, or is it scattered throughout the company?
Near misses, or unknown predispositions to harmful
situations may be unaccounted for in your facility; performing
an internal safety audit will uncover those, saving you time, A worker’s hand could come into
productivity, and money, by avoiding potential accidents. What can go contact with a rotating object
wrong? (pulley) that “catches” it and
General vs. Targeted Audits pulls it into the machine.
Audits may tackle the safety concerns of an entire facility, or

one aspect or hazard. A targeted audit of a specific work area
or operation may be in order if the facility has experienced a
serious injury, or a series of injuries or near-misses. Carefully What are
Severe injury: possible loss of
develop a checklist to address any targeted audits; use our the potential
fingers or hand.
checklist in the back of this guide to help you. consequences?
When it comes to designing your facility safety audit, one

size does not fit all. Always err on the side of thoroughness
and detail. Often, a “minor” problem that was not deemed
important or was overlooked, such as a failure to follow It could happen as a result of
specific LO/TO procedures, can result in serious injury or, in the worker trying to clear a snag
the worst case, fatality. during operations or while doing
How could it
maintenance while the pulley is
The following are areas that may be included in a facility happen?
operating. Obviously, this hazard
safety audit. Depending on the type of facility you are in, scenario could not occur if the
some examples may not apply. The safety inspection checklist pulley is not rotating.
in the back of this guide is not meant to limit the areas for you
to audit, but to aid you in creating your own list of priorities.
Health & Safety Program, Safety Culture, Incentives

OSHA mandates that every company must have a health This hazard occurs very quickly.
and safety program. Employees should all be familiar with it. What are other It does not give the worker much
All employees, including temporary, clerical, and part-time contributing opportunity to recover or prevent
workers, should be trained to recognize and avoid unsafe or factors? it once his hand comes into
unhealthy situations. They should feel encouraged to make contact with the pulley.
suggestions regarding workplace health and safety. Safety
incentive programs should encourage workers to report
injuries or safety issues.
Job Hazard Analysis, Including Ergonomic Assessment

If workers in the same area or with the same job descriptions This determination requires
are suffering frequent injuries, complaining of pain, or some judgment. If there have
experiencing near-miss incidents, a job hazard analysis (JHA) been “near-misses” or actual
is in order. A JHA examines the relationship between worker, What is the cases, then the likelihood
task, tools, and work environment, with the goal of identifying likelihood this of a recurrence would be
hazards before they occur. Conduct JHAs for your entire hazard will considered high.
facility if you want to aggressively pursue a safe workplace. occur?
It is high due to multiple near
Start with the most hazardous jobs and work your way toward
misses having been reported
those with the fewest recordable injuries. A job hazard
in the last month.
analysis can be done as part of a safety audit or separately.
It is also helpful to identify possible hazard scenarios. When Example: The work of a lathe operator in a machining
a known hazard is brought to your attention, OSHA suggests department may require several steps. One of these
discovering: steps often results in flying metal shards or droplets
of cutting oil, which can impact the eyes, face, or skin.
• Environment: Where is it happening? These hazards are created by blowing the cutting fluid
• Exposure: Who or what is it happening to? and metal shards away from the lathe mounting plate
with compressed air. In a typical job hazard analysis
• Trigger: What is causing the hazard?
form, there may be more than one type of protection for
• Consequence: What is the outcome that would occur the lathe operator: lowering compressed air pressure;
should it happen? using a vacuum, brush or cloth to remove debris; and
• Any other contributing factors recommended PPE such as eye protection, gloves and
specific outerwear to shield the skin.
Each job carries its own unique hazards. The best way to
determine hazards is just by watching someone work.
Job Hazard Analyses: The Experts Speak

James Pryor, of American Safety and Health Management
Consultants, Inc., has conducted and been the subject of many
industrial safety audits.
“As part of a large corporation, I had the time and resources to

conduct a JHA. To me, the JHA, if conducted properly, is the single
most important tool to prevent accidents,” he explained.
The steps involved in a JHA are as follows:

• Select the job to be analyzed
• Break the job down into sequences
• Identify the hazards
• Determine preventive measures to overcome the hazards
For small to medium-sized companies, Pryor believes the role of the audit is important, but not critical.
“Generally, I have found the audit ranks low in priority. There are a variety of reasons for this. One primary reason is
that there appears to be no immediate benefit. Many times the audit becomes a to-do list with added costs in the eyes
of management or a political tool for the employees. Unfortunately, most audits are triggered by either accidents or
regulatory action,” Pryor said.
Many workers and managers learn primarily how to view safety as a series of events—behaviors that contribute to the
overall safety culture. Safety audits help measure workplace safety performance. The data obtained can be used to
apply more resources to those areas not in compliance.
“We can create the safest physical environment with the best policies, procedures, equipment, safety controls, and
safety training,” observed Dr. Judy Agnew, senior vice president of safety solutions for Aubrey Daniels International
and author of ‘Removing Obstacles to Safety: A Behavior-Based Approach.’ “When you add human beings, they will
do things in ways you did not predict. Employees will bypass safety guards and take other safety shortcuts. This is
not done because employees want to get hurt. Employees are attempting to get the job done efficiently, quickly, and
with quality.”
Figuring Out a Solution Prioritize Your Findings

There are four ways to determine preventive measures. In Once you have conducted your facility safety inspection or
order of preference, consider: audit, prioritize the hazards uncovered according to level
• Eliminating the hazard through engineering—increasing or likelihood of danger. Hazards that are likely to occur or
ventilation, changing equipment or tools reoccur should be addressed immediately, as should any
hazards that could lead to loss of life or serious injury.
• Containing the hazard with enclosures
• Administrative procedures like changing the sequence of Some organizations rate hazards as Urgent (U), Important (I),
steps or adding lockout/tagout (LO/TO) devices and Routine (R). By rating each finding this way, you can track
the frequency of each category in successive inspections and
• Using personal protective equipment (PPE), such as audits to shed light on the effectiveness of your safety effort.
goggles
Document & Store Your Audit Results

When auditing safety related to a job, use a team
approach. Be prepared to walk through and examine Your inspection and audit findings should be readily
equipment and facilities, review the appropriate paperwork accessible to management, contracted safety professionals,
and safety signage for all areas, and get feedback from co- or OSHA representatives. OSHA does not routinely request
workers who actually work in these areas. your self-inspection or audit results when commencing
an enforcement inspection. However, in some cases your
Ergonomics self-inspection or audit records may demonstrate to OSHA
that you are in the process of correcting a violation-worthy
Do not ignore the role ergonomics and body mechanics condition. In such cases the agency may view your audit
play in injury prevention, particularly regarding strains and records as a good-faith effort that you are working to improve
sprains. Many recordable injuries result from poor posture conditions, and not issue a citation. However, the reverse is
(especially affecting office workers), repetitive motion also true: if a finding was noted and never addressed, OSHA
(affecting office workers and manual laborers), and poor body could issue a citation.
mechanics (affecting employees who lift or use tools).
Ready to improve safety?

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True (Non)-Safety Stories

Most deaths and injuries on the job are avoidable. The following are real stories from OSHA Fatal Facts reports.
I-beam Strikes Worker
A 28-year-old laborer with four years of experience was How could this fatality been avoided?
working with two others to stack I-beams in preparation
for a construction project. It was a warm clear day and OSHA requires employers to:
he had been on the crew for this project for five weeks. • Instruct each employee in the recognition and
avoidance of unsafe conditions and regulations
The laborer was placing a 2" x 4" wooden spacer on the applicable to the work environment to control or
last stack of I-beams. The forklift driver drove up to the eliminate any hazards, in accordance with Title 29 Code
stack with another I-beam that was neither secured nor of the Federal Regulations (CFR) 1926.21(b)(2).
blocked on the forklift tines. The I-beam fell from the • Ensure that powered industrial trucks have loads that
tines, pinning the laborer between the fallen I-beam and are stable and secure and that persons are not allowed
the stack of beams. The laborer was killed. too close to the elevated portions, in accordance with
29 CFR 1926.602(c)(1)(vi).
DuraLabel PRO 300 • Ensure that proper personal equipment (the forklift
Print safety labels and signs up
to 4" in width with the DLP300. driver in this case did not wear a seat belt while
operating the forklift) is worn in all operations
where there is exposure to hazardous conditions, in
accordance with 29 CFR 1926.28(a).
• Ensure that the employer initiates and maintains a
safety and health program, in accordance with 29 CFR
1926.20(b)(2).
Explosion Kills Experienced Worker
A 45-year-old iron worker with 20 years of experience How could this fatality been avoided?
had just reported to a construction job. The job site
had a safety program in place and a competent person OSHA requires employers to:
was on site. • Take precautions to provide sufficient ventilation to
ensure proper combustion when operating portable
A blowtorch-type of portable propane heater was heaters/blowtorches in confined spaces, in accordance
being used. The torch flamed out, allowing gas to with Title 29 Code of Federal Regulations, Part
gather in the bilge area of a construction barge. The 1926.154(a)(2).
accumulated gas exploded with great force, killing the • Ensure that portable heaters/blowtorches are
worker. equipped with automatic shut-off devices to stop the
flow of gas in the event of flame failure, in accordance
As a result of its investigation, OSHA issued citations
with 29 CFR 1926.153(h)(8).
for two serious violations of OSHA standards.
Bulldozer Operator Burned
A crew of two was working on a roadway project. The How could this fatality been avoided?
44-year-old bulldozer operator had over 15 years of
experience. OSHA requires employers to:
• Train maintenance and operating personnel to
The bulldozer operator was preparing the road bed recognize potential problems with the operation of the
by using the machine to lift trees out of the way. A machinery.
hydraulic line to the right front hydraulic cylinder • Have competent persons perform periodic inspections
ruptured, spraying hydraulic fluid onto the engine of all operating equipment. Ensure that the employer
manifold and into the operator’s compartment. Upon initiates and maintains a safety and health program, in
contact with the hot manifold, the hydraulic fluid accordance with 29 CFR 1926.20(b)(1).
ignited, engulfing the operator in flames. The operator
died from the burns he received.
Following an inspection, OSHA issued citations for two

serious violations of OSHA standards:
• Frequent and regular inspections of equipment were

not made by competent persons designated by the
employer in accordance with 29 Code of Federal
Regulations (CFR) 1926.20(b)(2). It was determined
that the hydraulic hose had been installed backward
so that a bend in the fitting connection made contact
with the body of the bulldozer, resulting in wear and
abrasion of the hose at the connection. This was not
discovered during inspection of the machine.
• The employees doing inspections were not instructed
DuraTagTM Tag Stock
to examine the hoses for signs of wear and abrasion Tags are a quick and easy
as required by 29 CFR 1926.21(b)(2). way to label equipment
needing inspection.
Live Overhead Lighting Kills Electrician
A journeyman electrician was correcting an electrical How could this fatality been avoided?
problem involving two non-operational overhead lights.
He had not shut off the power at the circuit breaker Here’s what OSHA requires:
panel nor had he tested the wires to see if they were • The employer should not allow work to be done on electrical
live. He was electrocuted when he grabbed the two live circuits unless an effective lockout/tagout program is
wires with his left hand and then fell from the ladder. implemented [29 CFR 1926.416(a)(1)].
• The employer should not allow work to
As a result of its investigation, OSHA issued be done on energized electrical circuits
citations alleging two serious violations. OSHA’s or circuits which are not positively
construction standards include several requirements de-energized or tagged out [29 CFR
which, if they had been followed here, might have 1926.417(a) and .417(c)].
prevented this fatality.
DuraTagTM LO/TO Tag Stock - Implementing a lockout/

tagout program is vital for electrical safety.
Visual Communication Inspection

Properly placed signs and labels can not only help ensure
OSHA compliance, but can also improve safety and
productivity.
As you conduct your facility safety inspection or audit,

perform a visual communication inspection. The following
are common signs and labels that improve safety and
OSHA compliant
productivity. Danger sign
Type of label Description
HazCom 2012 (OSHA req.), GHS (international standard)
Chemical hazard Use HazCom labels for any hazardous chemicals in your
communication facility. If they will be shipped internationally, they must have
GHS aligned labels. Lack of HazCom labeling contributed to HazCom 2012
OSHA’s number-two violation in 2013 and 2012. GHS
Use OSHA & ANSI compliant safety signs to warn against

Health and safety labels: Crush Hazard!
various hazards of different danger levels and take Keep out during
operation.
Danger, Warning, Caution, Moving parts will cause Hazardous Vapors Keep Aisles
precautions such as PPE. Important for safeguarding serious injury or death. Exposure may cause
Clear
Notice, and Safety signs
internal bleeding,
infertility, or death.
employees and staying compliant. Forklift area
Use these die-cut labels to warn of arc flash danger, require specific PPE,
Arc flash warning labels
and describe safety boundaries. OSHA/NFPA 70E/CSA/ANSI-compliant.
NFPA compliant labels describe health risk, flammability, and volatility

NFPA 704 labels of any hazardous material. Ideal for first responders in the event of an
emergency.
Use premium vinyl, high-tack, oily-surface, extreme temperature,

phosphorescent, magnetic, and other tapes to print exit and wayfinding
Custom labels signs, equipment identification, and almost any sign or label you can
think of. They can be mounted on sign blanks or adhered directly to
any surface.
Flexible, printable, photoluminescent, and non-skid floor marking tapes

Floor marking can mark traffic lanes for forklifts, docks for pallet jacks, or any other way
you want to mark a facility floor.
The type of facility you have will determine which codes you need to
comply with; the ANSI/ASME A13.1 standard is most common, while
Pipe marking
the IIAR standard applies to ammonia piping systems. In general, the
contents and flow direction of all pipes should be marked.

PREPARING FOR AN OSHA INSPECTION
The Occupational Safety and Health Act of 1970 authorizes OSHA to conduct workplace inspections to determine whether
employers are complying with the agency’s standards for safe and healthful workplaces. Although most businesses fear a
random inspection, OSHA has found that random inspections produce safer workplaces.
Workplace Inspections within those high-risk SIC codes, the Site-Specific Targeting
(SST) inspection plan focuses on employers with the highest
Random inspections are usually unannounced. They Days Away, Restricted or Transferred (DART) rates and Days
must be conducted at a reasonable time, generally during Away From Work, Injury and Illness (DAFWII) case rates. The
normal work hours. Depending on the size of the facility information is collected from OSHA’s 300 and 300A forms.
and complexity of the operation, the inspection could take
several days. Some high-risk SIC codes include:
Just because OSHA can inspect your workplace doesn’t • Logging (SIC 241)
mean that it will. After all, there are only a few thousand • Cut Stone and Stone Products (SIC 328)
OSHA inspectors and more than 7 million workplaces in the
U.S. The likelihood that you’ll be inspected is slim, unless • Trucking Terminal Facilities (SIC 423)
your industry is categorized as high risk. According to a • Roofing, Siding, and Sheet Metal Work (SIC 176)
2013 AFL/CIO report: “…federal OSHA inspectors can only • Camps and Recreational Vehicle Parks (SIC 703)
inspect workplaces once every 131 years on average, and
state OSHA inspectors would take 76 years to inspect all • Landscape and Horticultural Services (SIC 708)
workplaces.” OSHA has established priorities that dictate • Animal and Marine Fats and Oils (SIC 2077)
the workplaces it will inspect.
• Concrete, Gypsum, and Plastic Products (SIC 327)
If you have been previously inspected by OSHA and have had • Taxicabs (SIC 412)
serious or willful violations, you can expect to be inspected
repeatedly. Otherwise, the following will increase the
likelihood of an OSHA inspection: Exemptions
• Imminent danger refers to any known condition or
Are You Exempt?
practice that may cause death or serious harm to workers, Workplaces with 10 or fewer employees, and many
requiring immediate corrective action. Imminent danger agricultural businesses, are exempt from random
is typically revealed through a whistleblower notifying OSHA inspections. Low-risk workplaces, such as office
OSHA of a dangerous situation or based on findings from environments, are unlikely to receive an OSHA visit unless a
a random inspection. complaint has been logged. Companies enrolled in OSHA’s
• Fatality/catastrophe inspections are triggered by work- SHARP or VPP programs are also unlikely to be targeted.
related incidents that result in the death of a worker or
the in-patient hospitalization of three or more employees.
OSHA must be notified of these incidents within eight
hours of it happening. Media reports can alert OSHA
to the need for a fatality/catastrophe inspection, if not
reported by the employer right away.
Prepared for an inspection?
• Complaint/referral inspections are typically received Create a safe facility
from a current or recently discharged employee or a labor environment with safety signs
and labels. Choose Toro for
union. Referrals may come from doctors who have treated
an all-in-one labeling system.
workers, local activists, OSHA inspectors themselves or
various other sources.
• Programmed inspections are regularly scheduled in
high-risk industries, as classified by Standard Industrial
Classification (SIC) code. There are more than 10,000
different SIC codes covering every kind of business. If
the SIC code under which your workplace falls has a high
number of injuries reported to the U.S. Department of
Labor, then your workplace will be on a list that may be
inspected at random by an OSHA compliance officer. From
Getting Your Company Ready required safety data sheets (SDS) for all hazardous materials,
and are they properly labeled? OSHA has placed extra
The best way to prepare for an OSHA inspection is to be a emphasis on record-keeping to prove there is a track record
conscientious company that puts the safety of its workers of prioritizing safety.
at the forefront of its corporate values. Safety culture is
a top-down proposition: When management takes safety Training & Education
seriously, it sets the tone for safe work practices and attitudes
throughout the company. Have you conducted all the training required by your safety
program? Forklift safety, hazard communication training and
There are three areas of your business to pay attention to that lockout/tagout are examples of important safety programs
will have a major impact on your company’s overall safety as your company may need.
well as its readiness to face an OSHA compliance audit:
Safety Inspection
Documentation Try conducting your own safety inspection, using the talents
Is all your documentation thorough and accurate? Are of the most knowledgeable and informed experts in your
your written safety programs current? Have you accurately company, as well as some people whose inexperience may
recorded injuries in your OSHA Form 300 log? Is everyone lend fresh eyes to the task. Use a thorough checklist and be
fully trained on HazCom 2012, have you received all of the rigorous about correcting the findings as soon as possible.
DON’T TAKE CHANCES

WHEN YOU DON’T HAVE TO
Boost your LO/TO safety program with locks, tags, kits, and more
Call 877.534.5157 or visit Store.GraphicProducts.com/Loto

Top 1O OSHA Violations for 2O16

OSHA issued the most citations for these common safety issues. It’s easy to view these hazards as “regulation issues” or “OSHA
issues,” but the reason these citations are written is because there is high likelihood of serious injury or death if not resolved.
These 10 issues tend to change little from year to year. As you conduct your safety audit, be extra vigilant regarding these areas:
2015 2014 2013

2016 Ranking Ranking Ranking Ranking
1. Fall protection: Failure to use fall arrest systems, guardrails, safety nets, etc. 1 1 1
2. Hazard communication: Poor labeling, lack of training, insufficient safety data

2 2 2
sheets and right-to-know information
3. Scaffolding: Unsecured planks, not level, no guardrails, etc. 3 3 3
4. Respiratory protection: Poorly fitting respirators, improper storage and cleaning 4 4 4
5. Lockout/tagout: Insufficient LO/TO safety program, lack of tagging, unclear

5 6 8
authorization roles
6. Powered industrial trucks: Improper forklift training and certification, lack of skill
6 5 6
and training
7. Ladders: Improper storage and use of ladders 7 7 7
8. Machine Guarding: Pinch points, missing guards, etc. 9 9 10
9. Electrical, Wiring Methods: Unsafe equipment or installation, environment, work

8 8 5
practices, improper PPE, improper LO/TO
10. Electrical, General Requirements: Unsafe practices while working around live
10 10 9
wires, power lines, and other electrical hazards
When the Compliance Officer Knocks When advance notice is given, it is the employer’s
responsibility to promptly notify the authorized representative
The OSHA compliance officer (inspector) typically will show of employees when the inspection will occur, if the identity of
up without warning at your place of business, except in the such representative is known to the employer.
following cases:
• When apparent imminent danger, to enable the employer Right to Inspect

to abate the danger as quickly as possible. There is not an assumed “right to inspect” just because your
• In circumstances where the inspection can most effectively business has been chosen for an audit. You can notify the
be conducted after regular business hours or where inspector that your company does not permit warrantless
special preparations are necessary for an inspection. OSHA inspections. If you refuse their entry in this manner,
• Where necessary to assure the presence of it is likely that OSHA will apply for an inspection warrant.
representatives of the employer and employees or the The warrant may arrive with the inspector between a few
appropriate personnel to aid in the inspection. hours and a few weeks later. Warrants spell out exactly what
inspectors are allowed to do at your workplace, where they
• In other circumstances where the OSHA area director can go and how long they can stay.
determines that giving advance notice would help ensure
an effective and thorough inspection.
Get a detailed look at OSHA’s Top 1O violations for

2016 at: GraphicProducts.com/infographics
Tips for Communicating with Your Compliance Officer
A pre-designated representative of the employer should

accompany the inspector at all times, and it should
always be the same person. Two or more representatives
could supply conflicting information, which could arouse
suspicion on the part of the inspector.
You can always take a “time out.” If the representative is

unsure of how to answer the inspector say, “I don’t know,
but let me find out.” Then, take time out and consult
with a manager or someone knowledgeable.
Have records and documents in order so the inspector

can readily address them.

The Four Parts of an OSHA Inspection

Every OSHA inspection consists of a presentation of credentials, an opening conference, a facility walk-through, and a closing
conference.
1. Presentation of Credentials: Sometimes there will be two found on the business card the compliance officer gave
officers. After introducing him/herself, the compliance you at the outset of the inspection.
officer will show an ID card and announce that he or she 4. Closing Conference: After the walk-through has
has come to conduct an OSHA compliance inspection. It’s been conducted, the compliance officer meets
always a good idea to show courtesy and respect to the with the employer to discuss his or her findings. An
compliance inspector. employee representative is entitled to be present at
2. Opening Conference: During the opening conference this conference, but ultimately can be denied by the
the compliance officer will explain the reason for the employer representative. According to Moran, when the
visit and describe the scope of the inspection. The OSHA officer mentions a violation you should never say
compliance officer(s) will ask to see paperwork, such as anything that could be taken as agreement with his or her
the OSHA form 300 log and documentation about your statement, in the event that you want to contest it later.
hazard communication, safety training, lockout/tagout In fact you may disagree with the OSHA officer, but do
programs, etc. Equipment inspection and maintenance not get into an argument. Closing conferences can also
records, as well as safety meeting minutes, safety and be conducted over the telephone by request. It is wise to
health programs, etc., are also likely to be requested, audio and or video record the closing conference.
which is optional unless a warrant states that it is not.
The officer will ask several questions about the nature of After the inspection, request any sample and monitoring
the business and there may be questions about matters reports from OSHA. If the compliance officer noted any
related to hours worked and employee injury rates. problem areas, make appropriate improvements to address
3. Walk-through: The compliance officer will examine the his or her concerns. If you are using counsel to work with
entire facility, observing closely the working conditions OSHA, provide the counsel with copies of any documentation,
and practices to see what hazards, if any, are present. including photos and video, taken during the inspection.
He or she may question foremen or supervisors. If it Your OSHA counsel should formally request of OSHA that
is a health inspection and the compliance officer is it maintains confidentiality regarding any trade secrets or
an industrial hygienist, he or she may take chemical proprietary information disclosed during the inspection.
samplings for further analysis. Always accompany the
Any citations will be issued up to six months from the time
compliance officer and duplicate the inspector’s notes as
of inspection. It is the employer’s duty to post the citation
well as photographs and measurements, in the event that
in a prominent workplace location per OSHA’s instruction.
you choose to dispute OSHA’s findings later. According
As an employer, you have the right to contest any citations
to Mark Moran, author of The OSHA Answer Book, “The
or penalties in writing; that is why you should take thorough
vast majority of OSHA violations are based on what the
notes, including the time and date of all notations and
employer said to the inspector, not what the employees
observations.
said, or what the inspector saw during the inspection.”
Never give estimates, and never be reluctant to disagree
with the compliance officer. It’s also recommended that
you never admit fault as that will be taken as admission of
violating a standard.
Employees have the right to choose a representative
(including union representation) to accompany
the compliance officer during the inspection. If the
compliance officer wants to interview employees, stand
out of earshot but not out of sight. Your employees
are legally protected from discrimination for exercising
safety and health rights, which means they cannot be
discriminated against for what they tell the compliance
officer. However, in the event that your compliance officer Keep important papers organized and easy to find at a moments notice.
is giving orders to employees or acting in a way that you DuraLabel Lobo prints labels from ½" to 2" in width and is ideal for labeling
question, call the OSHA area director. The number can be shelves, bins, office equipment, and more. Call 877.534.5157 for more info.
Here are the six types of OSHA violations, as taken from the agency’s website:
• Other Than Serious Violation: A violation that has a direct If an employer is convicted of a willful violation of a
relationship to job safety and health, but probably would standard that has resulted in the death of an employee,
not cause death or serious physical harm. A proposed the offense is punishable by a court-imposed fine or by
penalty of up to $7,000 for each violation is discretionary. imprisonment for up to six months, or both. A fine of up to
A penalty for an other-than-serious violation may be $250,000 for an individual, or $500,000 for a corporation
adjusted downward by as much as 95 percent, depending may be imposed for a criminal conviction.
on the employer’s good faith (demonstrated efforts to • Repeated Violation: A violation of any standard,
comply with the Act), history of previous violations, and regulation, rule, or order where, upon reinspection, a
size of business. When the adjusted penalty amounts to substantially similar violation can bring a fine of up to
less than $100, no penalty is proposed. $70,000. To be the basis of a repeated citation, the
• Serious Violation: A violation where there is substantial original citation must be final; a citation under contest may
probability that death or serious physical harm could not serve as the basis for a subsequent repeated citation.
result and that the employer knew, or should have known • Failure to Abate Prior Violation: Failure to abate a prior
of the hazard. A mandatory penalty of up to $7,000 for violation may bring a civil penalty of up to $7,000 for
each violation is proposed. A penalty for a serious violation each day the violation continues beyond the prescribed
may be adjusted downward, based on the employer’s abatement date.
good faith, history of previous violations, the gravity of the
alleged violation, and size of business. • De Minimis Violation: De minimis violations are
violations of standards which have no direct or immediate
• Willful Violation: A violation that the employer knowingly relationship to safety or health. Whenever de minimis
commits or commits with plain indifference to the law. conditions are found during an inspection, they are
The employer either knows that what he or she is doing documented in the same way as any other violation, but
constitutes a violation, or is aware that a hazardous are not included on the citation.
condition existed and made no reasonable effort to
eliminate it.
Penalties of up to $70,000 may be proposed for each
willful violation, with a minimum penalty of $5,000 for
each violation. A proposed penalty for a willful violation
may be adjusted downward, depending on the size of the
business and its history of previous violations. Usually, no
credit is given for good faith.
REQUEST YOUR FREE CATALOG TODAY

Labeling & Signage Spill Control & Containment
Floor Marking & Wayfinding Services
Lockout/Tagout
Call 877.534.5157 or
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Case Study
Bruce MacKender, member & industry relations
manager for the Society of Manufacturing Engineers
(SME), recalls his former company’s experience with
industrial safety audits.
“I was the operations manager for the Delta

Engineering Division of Western Electronics, a
Tualatin, OR manufacturer of light-gauge precision
sheet metal used in the high-tech electronics and perform their work which resulted in potentially unsafe
telecommunications industries. This operation had conditions. In the end, we learned that we needed to
a standing safety committee—a voluntary team of make a small investment of additional time to find
employees that covered all days and hours of our alternative methods for performing these operations.
operation and explored every part of our manufacturing
“Another major area of concern was the eye wash
facility each week to look for possible unsafe
station. We found that eye wash stations need to be
conditions. The team usually included one of our team
monitored weekly, as they get contaminated with dust
members from the Quality Department.
quickly when they are not used. The
“Because of training and discipline, they were well- irony is that while eye wash stations
suited to look for items and areas of “compliance” and are strategically installed throughout
“non-compliance.” Each week, the safety committee the operation with the intention of
would perform a 45- to 60-minute safety audit in one being “first aid” devices, they can
area of the operation. As an example, one week we’d actually become safety hazards that
look at the area where we stored our solvent-based can potentially cause greater damage
materials for our painting and finishing operation, then to an injured eye when the stations
the next week we’d examine our forklift operations, are contaminated.
the following week we’d review our air supply systems
“Through our process and through our OSHA
(compressors and air lines)—slowly, but surely making
experience, we also became more knowledgeable and
our way around our 60,000 square foot manufacturing
aware of hearing and breathing protection—ensuring
plant to ensure we were running the operation as safely
that our respirators’ filtering systems were working
as we could and not putting any of our 100+ employees
properly and we had the correct filtration systems for
at risk. We conducted these industrial safety audits on
each different application.
an ongoing basis.
“Our OSHA experience was ultimately very positive.
“One day, we were surprised to find that three OSHA
We learned that being proactive in addressing our
representatives were asked to inspect the plant
infractions helped, too, and to communicate our good
based on a call from a former employee. While it was
intentions in the form of letters, photographs, and proof
a hellish week, we did learn a great deal from the
that we’d took corrective action and created training
experience—that with the best of intentions we had not
and education programs where they were needed.
discovered on our own. For example, we learned that
one of the most common OSHA infractions occurs in “In the two years I was with Western Electronics, we
the machine guarding area. Our company had dozens were very fortunate because we had no major industrial
of small fractional horsepower bench grinders used accidents. On the positive side, we did conduct First
for de-burring of parts. Frequently, small resting tables Alert First Aid Training so we were probably better
and glass windows prepared for emergencies than most companies.
would be removed
to allow the “Most importantly, we did a great job of creating a
operators better heightened sense of awareness of safety issues for our
access to the employees and team members, from their arrival in the
grinding wheel and parking lot to the time they left at the end of their shift.”
SIGNS & LABELS FOR YOUR FACILITY
A properly placed sign or label can mean the difference between compliance and violation, or even life and death. Because
visual communication can succeed when other kinds of communication fail, OSHA requires different kinds of labeling to make
workers aware of all kinds of hazards, including chemicals, arc flash, and others.
OSHA’s General Duty Clause The Four C’s of Labeling

OSHA’s General Duty Clause, which mandates that employers Safety signs and labels within a facility must adhere to
provide a workplace “free from recognizable hazards that… the “Four Cs”: Comply, Communicate, Connect, and be
are likely to cause death or serious harm,” has resulted in Consistent.
the non-binding labeling guidelines put forth by standards
of organizations and essentially required by OSHA. These • Comply: Guidelines for safe signage put forth by ANSI
standards may come from NFPA, ANSI or other organizations. (Z535) have been adopted as code by OSHA. Z535
This means that should your business be inspected by OSHA, requires specific color formats for differing danger levels:
your use (or misuse) of labels and signs will be noticed. Danger, Warning, Caution, Safety, Notice, and Biohazard.
The easiest way to comply with this standard is to use
a thermal transfer labeling system with preformatted,
July 29, 2013—OSHA Cites Glass Manufacturer in Zanesville, OH, for
colored labels that you can print your own safety
Safety and Health Violations, Including Lack of Proper Exit Signs. The
message on.
citation included a repeat violations for exit directions being unmarked.
Additional violations included lack of fall protection for workers on • Communicate: Signs and labels must be clearly written
open-sided platforms; nonworking emergency lighting; failing to and accurately state the hazard at hand. It is required by
require the use of head protection for workers exposed to overhead HazCom 2012 that all employees are trained using Safety
hazards; lack of an emergency eyewashing station for exposure to Data Sheets (SDS) in regards to the safe handling of
corrosive materials; and the use of an electrical panel box that was not chemicals and ability to identify compliant labels.
protected from water and damp conditions. • Connect: The sign or label must connect the viewer with
a specific item or situation, ie. a hazardous machine, or
August 20, 2013—OSHA Cites a Vinyl Window Manufacturer in Newark, location, such as an area where hearing protection must
NJ for Failure to Label Containers of Hazardous Chemicals and Lack of be used.
Proper Exit Signs. Amongst the improper sign and label violations were • Be Consistent: Compliance ensures consistency, because
others including; keeping exit routes free and unobstructed, providing colors and types of messages become familiar to viewers.
lavatories with hand soap and providing workers with proper PPE for But not all signs and labels are governed specifically by
eye and face protection. code; if other labels are used—for instance as instructional
aids or wayfinding—they should be consistent in both looks
(color and layout) and messaging to ensure that everyone
January, 2013—OSHA Cites Billings, MT Company for Safety Violations, understands.
Including Lack of Signs on Permit Spaces.
Compliance with DuraSuite

Ensure label compliance with DurasuiteTM labeling software for
arc flash, GHS/HazCom 2012, NFPA/RTK, pipe markers, and
more. Includes 1,800+ useful OSHA/ANSI compliant symbols.
Included free with DuraLabel desktop printers.
877.534.5157 | GraphicProducts.com

What Material is Right for Your Job?

Labels come in many widths and materials. Although
DuraLabel Premium Vinyl is sufficient for a large percentage
of industrial labeling tasks, many other materials are
available, such as high-temp poly, extended-life vinyl, oily
surface, magnetic, chemical-resistant, ultra-aggressive,
BoldGlo phosphorescent, low-halogen, reflective vinyl, and
dozens of others. (DuraLabel carries more than 50 kinds of
labeling supplies for virtually any sign and labeling need.)
Before you start labeling everything in your facility, make

sure you have the right material for the job. DuraLabel
Avoid citations. Faded or worn labels and signs should be
Premium Vinyl is chemical, weather and abrasion-resistant. replaced. DuraLabel offers more than 50 different types of
Extended-life vinyl might be a better choice if the label is labeling supplies. Let us help you find the best supply for your
going to be outdoors and exposed to sun and rain. Low- specific labeling project. Call us today at 877.534.5157.
halogen tape is best with stainless steel.
Examples of DuraLabel supplies & how they can be used for specialized situations:
• DuraTag stock: A high- • Metal Detectable: Labels,
performance tag stock that or pieces of labels, made
is extremely difficult to rip or with this material can
tear. Can be hung without a be found using a metal
grommet, by punching a hole detector. Excellent for
in the tag. use in applications where
contamination of products or
• Embossable Poly Tape: Allows processes must be detected.
handwritten information to be
permanently added to a label. • Permanent: Consider
aggressive adhesives that last
• Extended-Life: These materials up to five years outdoors.
are thinner, reducing the ability
of moisture and air to get • Temporary: Temporary labels
under the edge of the label. or signs may identify work in
progress, warehouse shelves,
• Fluorescent HiViz Tapes: storage bins, and signage for
Provide bright colors to trade shows. They’re usually
produce attention grabbing discarded or reused. For
labels and signs reuse, magnetic labels or
signs, poly cling labels and
repositionable labels are a
good option.
Different Surfaces Call for Different Labels

Not all surfaces are created equal. Whereas most industrial
Not All Surfaces Are
surfaces will work well with Premium Vinyl, other surfaces Created Equal
present unique adhesive challenges for facility managers.
Here are some specialized surface adhesives that are
available through DuraLabel.com.
• Curved surfaces, rough surfaces: Special adhesives and
materials such as Conformable Polypropylene Tape adhere
to curved surfaces and won’t come loose.
• Sensitive surfaces: Electrostatic Dissipative Tape (ESD) is
the best choice for static-sensitive equipment. It can also Conformable Electrostatic
Polypropylene Tape Dissipative Tape
help eliminate damage to electrostatic sensitive products
by reducing static build-up during label printing, during
removal of the backing, or even application.
• Low energy surfaces: For rough surfaces or those with
low energy choose High-Tack Tape. Examples of low energy
surfaces include some plastic, metal and painted surfaces.
• High wear areas: For longer-lasting signs in the
most demanding environments, a popular choice is
DuraLabel Extended-Life Vinyl, which works well in plants, High-Tack Tape Extended-Life Tape
warehouses, and other industrial facilities that get high
traffic and contact from machines and workers.
Sign & Label Inspection Guidelines

Labels should be properly maintained to ensure legibility
and readability. Under normal conditions, outdoor labels will
last about five years. Labels used indoors will typically have
a longer life, depending on the environmental conditions.
Labels and signs should be inspected about once a year.
Inspection frequency depends on how long ago the signs

were installed, exposure to weather extremes, and other
factors. Edges or corners of a label starting to curl up
indicate early label failure.
Also look for faded labels and damaged labels. Dirty labels
or signs should be cleaned. Does the information need to
be updated? Have new standards been introduced? Do they
need to be translated into another language to effectively
inform workers for whom English is a second language?
Don’t neglect to include equipment labels that came already

applied by the manufacturer in your inspection. They provide Pay special attention to outdoor signs and labels when
important safety information, and if damaged or missing they inspecting. Exposure to sun, wind, rain, and snow may cause
need to be replaced. wear and tear to your visual communication.

APPENDIX A: THE TOP 6 SAFETY SIGNS & LABELS
Is your facility optimized for visual safety communication? If you want a safe facility, consider where you can apply the top six
safety signs and labels in and around your buildings.
1. OSHA & ANSI Z535—Compliant Safety Signs

ANSI’s Z535 standard lays out guidelines for the safety and hazard signs we’re all familiar with. OSHA has adopted this
standard and has made it mandatory for compliance. The typical format is white with a colored header across the top,
containing a signal word: Danger, Warning, Caution, Notice, Safety, and Biohazard. Sometimes message panels can be black
or split-panel with white and black areas containing a safety message and pictograms.
DANGER: Red header with white type. Danger signs CAUTION: Yellow header with black type. Caution signs
indicate an immediate hazard which, if not avoided, will indicate a potentially hazardous situation which, if not
result in death or serious injury. Danger signs should be avoided, could result in minor or moderate injury. Caution
reserved for the most serious hazards and signify special signs are used in areas where potential injury or equipment
precautions are necessary. damage is possible, or to caution against unsafe practices.
Crush Hazard! Keep Aisles

Keep out during
operation. Clear
Moving parts will cause
serious injury or death.
Forklift area
WARNING: Orange header with black type. Warning signs NOTICE: Blue header with white italicized type. Notice signs
are one hazard level below danger signs. They describe provide general information that is important or relevant to
a hazard which, if not avoided, could result in death or a building, an area, a machine, or equipment. Notice signs
serious injury. address practices not related to personal injury.
Keep Out!
Hazardous Vapors
Exposure may cause
internal bleeding,
infertility, or death.
BIOHAZARD: Orange header

or background. The word
BIOHAZARD GENERAL SAFETY: Green header with white type. Safety signs
are used to provide notices of general facility practice, rules
BIOHAZARD or BIOLOGICAL relating to health, first aid, medical equipment, sanitation,
HAZARD must be black. The housekeeping, and
biohazard symbol can be black,
fluorescent orange, or an
suggested general safety
measures. The type on EYE WASH
orange-red color. Background the green header should Emergency
color is optional as long as there state the purpose simply:
is sufficient contrast for the “SAFETY INSTRUCTIONS,” Eye Wash
biohazard symbol to be clearly No food or drink “EYE WASH,” or Fountain
defined. in this area. “SAFETY SHUTDOWN Keep area clear.
PROCEDURE.”
APPENDIX A: THE TOP 6 SAFETY SIGNS & LABELS
2. Arc Flash Warning Signs 5. Pipe Markers

Arc flash signs, with either a danger or a warning header, In facilities that have significant piping systems, pipe
inform workers and others about dangerous arc flash marking is extremely important for safety as well as
hazards, warning them to stay away from equipment that maintenance. Both ANSI and ASME codes indicate
presents an arc flash danger. Arc flash signs also inform that pipes used to convey, distribute, mix, discharge,
workers about required personal protection equipment and control fluid flow should be marked to show their
(PPE) and/or a boundary that must be maintained around contents, potential hazard type, and the direction of flow.
the work area. Properly labeled pipes improve safety and productivity by
providing employees and emergency responders with key
information about piping system contents.
6. Wayfinding Signs
Wayfinding signs and labels can be found on exits,
3. HazCom 2012 Labels entrances, restrooms, fire escape routes, buildings,
As part of OSHA’s Hazard Communication Standard (HCS), departments, corridors, hallways, and stairwells.
all hazardous materials, such as industrial chemicals, Wayfinding is the process of organizing spatial and
pesticides, solvents, etc., must be identified with HazCom environmental information to help users find their way.
2012 labels. Aligned with the United Nations’ Globally Graphic standards should include consistent typeface
Harmonized System (GHS), HazCom 2012 labels have and size, as well as space for margins and between
1-5 diamonds with pictograms symbolizing the specific words. Signs must be very readable and must comply
kind of hazard. Each label must have hazard statements, with Americans with Disabilities Act (ADA) standards.
precautionary statements, and signal words. Keep in mind that wayfinding signage may need to
change frequently because of relocations, new hires,
reorganizations, retirements, and vandalism. Signage
should be durable, vandal-resistant, and cleanable.
4. NFPA 704 (NFPA Diamond) Labels

These labels, created by the National Fire Protection
Association, describe the hazard level for hazardous
materials in a quick visible format, ideal for first
responders and workers who come in contact with the
substances. Numbers from 0-4 (low to high) are paired
with colored diamonds to
indicate specific dangers.
Health risk is associated
with blue, flammability
with red, and instability
with yellow. Pictograms
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24
APPENDIX B: SAMPLE FACILITY SAFETY
INSPECTION CHECKLIST
The checklist below is targeted toward general industry and may not include all categories your company needs to review. Please note
that this checklist is used for informational purposes only and does not guarantee compliance with OSHA regulations or policies.
Facility Location: ________________________________ Evaluated by: _____________________ Date: _____________
Emergency Preparedness
Yes □ No □ Are building evacuation drawings that indicate exit routes and staging areas for assembly outside the
building up to date and posted near doorways?
Corrective action: ____________________________________________________________________
Person responsible: ____________________________________________ Due date: _____________
Yes □ No □ Do all employees understand their evacuation routes?

N/A □ Corrective action: ____________________________________________________________________
Additional inspection requirements may apply according to local regulations.
Yes □ No □ Are all fire doors to storage, telephone equipment, and power rooms in working order, unobstructed,
and closed?
Open fire doors increase the speed at which fire spreads and allow smoke to circulate more freely,
causing an increased risk to both occupants and equipment.
Yes □ No □ Are emergency exits unlocked and accessible?

Yes □ No □ Are fire extinguishers installed in appropriate locations and not further than 150 feet apart? Are
extinguishers clearly marked and unobstructed by equipment or materials? Have the extinguishers been
inspected within the past 12 months?
ABC-rated dry chemical extinguishers are appropriate in most areas. They should each have attached
inspection tags that indicate they have been inspected within the last 12 months.
Yes □ No □ Are hand-held extinguishers mounted on walls as opposed to being stored on the ground or in file
cabinets? Do employees know how to use fire extinguishers?
OSHA requires portable fire extinguishers to be mounted on a wall. Extinguishers stored on the ground
are likely to be moved and not replaced in the same location, causing the extinguisher to not be where
expected when needed during an emergency.

APPENDIX B: SAMPLE FACILITY SAFETY INSPECTION CHECKLIST
Fire Protection
Yes □ No □ Are wall, floor, and ceiling penetrations for cables, wires, pipes, and mechanical systems (such as
ductwork) sealed to prevent the spread of fire and smoke?
Sealed wall penetrations prevent the spread of fire and smoke from one room to another. Penetrations
can be sealed with drywall, fire-retardant pipe seal or firestop pillows.
Yes □ No □ Are flammable and combustible liquids stored in approved flammable storage cabinets?
Quantities of flammable and combustible liquids in excess of the following quantities should be stored
in approved flammables storage cabinets:
• 25 gallons of Class IA liquids (flashpoint below 73 degrees F. and boiling point below 100 degrees F.)*
• 120 gallons of Class IB, IC, II or III (flashpoint below 73 degrees F. and boiling point above 100
degrees F.)*
*Refer to the product safety data sheet (SDS) or MSDS grandfathered in to determine its flammability/
combustibility class.
Yes □ No □ Are “No Smoking” signs posted in appropriate areas, and no smoking rules enforced?
Yes □ No □ Have the facility’s sprinkler and/or fire alarm systems been inspected in the past 12 months? Is the fire
N/A □ suppression system tagged to verify this inspection?
Yes □ No □ Do sprinkler heads have at least 18 inches of vertical clearance from material stored below?
This clearance is required by OSHA and is necessary for proper functioning of the sprinkler system.
Hazard Communication & Substances
Yes □ No □ Does the facility have a written hazard communication program, including a complete chemical list and
file of safety data sheets (SDSs) for chemicals used and stored in the facility? Are these SDSs accessible
to all employees, visitors, and contractors for review upon request? Does the written program describe
how the employer will meet the requirements of OSHA’s Hazard Communication Standard?
SDSs should be on file for solvents, fuels, batteries, cleaners, lubricants, and other potentially hazardous
materials.
Yes □ No □ Are all chemical containers closed and properly labeled with the identity of the chemical, the name
and address of the manufacturer, and appropriate hazard warnings such as corrosiveness, toxicity, or
flammability?
Yes □ No □ Have all employees received training on the hazardous chemicals in their work area?
OSHA’s Hazard Communication Standard requires employers to provide training to employees that
addresses:
• The requirements of the OSHA Hazard Communication Standard
• Location of the company’s written Hazard Communication program, SDSs and chemical lists
• Methods to detect the presence or release of a hazardous chemical in the work area
• The physical and health hazards of the chemicals in the work area
• Measurements employees can take to protect themselves from these hazards
• A detail of the employer’s chemical labeling system
Refer to 29 CFR 1910.1200, OSHA’s Hazard Communication Standard, for more information and a
complete list of requirements.
Yes □ No □ Are spill cleanup absorbents available?

Yes □ No □ Are food, beverages, etc. kept out of areas with hazardous substances?

Housekeeping & Storage
Yes □ No □ Are walkways leading to and from the facility adequately maintained to minimize slips and falls from ice
N/A □ and snow?
Yes □ No □ Are the building’s gutters, downspouts, and ice-melting cords in proper condition and adequate to draw
N/A □ water and ice accumulation away from walkways?
Yes □ No □ Is ice melt or sand readily available near exits that are likely to accumulate ice?
Yes □ No □ Are floors clear of oil, chemicals, or objects that could cause a slip, trip, or fall?
Yes □ No □ Are containers and boxes stored to avoid the possibility of heavy objects falling?
Yes □ No □ Are stairways, emergency exits, etc. kept clear and marked to glow in case of power outage?
Electrical
Yes □ No □ Are electrical panels and circuit breakers labeled? Are outdoor circuit breaker panels secured with locks?
The wording on the label of a panel or circuit should adequately identify the panel and circuits so
emergency personnel or the operating engineer can rapidly identify them for emergency shutdown or
disaster recovery. Standardize names given to on-site panels to avoid confusion.
Yes □ No □ Are all circuit panels unobstructed and accessible to employees? Is the space in front of all circuit
panels not less than 36 inches deep and 30 inches wide, and free of stored materials?
Yes □ No □ Are extension cords used only temporarily?
OSHA and the National Electrical Code do not allow extension cords to be used as permanent wiring.
Only use surge protectors on equipment (computers, printers, etc.) when recommended by the
manufacturer.
Yes □ No □ Are receptacles located within six feet of a water supply (sink, shower, pool) protected by ground fault
circuit interrupters (GFCIs)?
Ground fault protection is required in these areas due to the additional electrical hazards in wet
environments.

Tools & Equipment
Yes □ No □ Are tools and equipment cords in proper condition?
Look for damaged cord insulation, missing ground prongs on cord ends, and cord repairs made with
tape.
Yes □ No □ Do tools and equipment have appropriate guarding in place?

Saw blades, flywheels, belts, chains, pulleys, gears, and electrical conductors are examples of
equipment typically requiring guarding.
Yes □ No □ Is eye protection available and worn during operations that create hazards from flying particles, liquid
N/A □ chemicals, or potentially harmful light radiation?
Eye protection should be worn while performing any cutting, grinding, nailing, spraying, or welding
operations. The ANSI Z87.1 designation on the eyewear indicates approved eye protection.
Yes □ No □ If respiratory protection is required, has the employer established and implemented a written
N/A □ respiratory protection program with site-specific procedures?
For information on respiratory protection programs, consult 29 CFR 1910.134(c) of OSHA’s safety
regulations. If respiratory protection is not required but used voluntarily by employees, the employer
should provide the employees with a copy of Appendix D of 29 CFR 1910.134, OSHA’s Respiratory
Protection Standard.
Recordkeeping & Enforcement
Yes □ No □ Are OSHA requirements for recording accidents, injuries, etc., up to date?
Yes □ No □ Are written records kept of safety training sessions?

Yes □ No □ Are all safety rules clearly communicated? Are all safety rules consistently enforced.
BE READY WHEN DISASTER STRIKES

STOP SPILLS BEFORE THEY CAUSE HAVOC
Prepare with our extensive lineup of spill kits & containment tools
Call 877.534.5157 or visit Store.GraphicProducts.com/Spill

Miscellaneous Safety Issues

Safety Issue: ____________________________________________________________________________________________
Corrective action: ________________________________________________________________________________________
Person responsible: _______________________________________________________ Due date: _______________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Safety Issue: ____________________________________________________________________________________________
Graphic Products®, DuraLabel®, PathFinder®, Toro®, Bronco® and Lobo® are Registered Trademarks of Graphic Products, Inc. ©2014, 2016. Graphic Products,
Inc. grants a limited revocable right to reuse portions of the material contained herein for non-commercial, internal, and educational/training use. Any use
beyond that described here requires the written consent of Graphic Products, Inc. Licensee agrees to reproduce the Trademark, Copyright, and Legal disclaimers
in all works created under this license.
SAFETY
IT’S YOUR CHOICE
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& Signage & Wayfinding Tagout & Containment
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Solutions for Safety & Visual Communication

DEVELOPING AN INSPECTION & AUDIT PROGRAM.......................... pg 2

4 Do you have proper PPE practices in place at Visual Communication Inspection

SIGNS & LABELS FOR YOUR FACILITY............................................... pg 19

pg 2O Are you using the best material for your

APPENDIX A: THE TOP 6 SAFETY SIGNS & LABELS...................... pg 22

APPENDIX B: SAMPLE FACILITY SAFETY INSPECTION

Content may have been updated to reflect the latest codes,

Workplace Injuries in 2O15

Considerations for an inspection and audit Effective programs thrive on

7 Tips for Safe & Effective Inspections

1. Prioritize your observations. If safety is your first concern, filter

2. Observe with intention. Practice observing work areas and

3. Be open-minded. Facts often defy our opinions.

4. Don’t trust first impressions. No matter how

5. Think like a journalist. A journalist

6. Don’t try to fix it right now. Resist the

Third-party machine safety specialists are often experts in identifying

Hazardous Materials (General) Emergency Preparedness

Audits may tackle the safety concerns of an entire facility, or

When it comes to designing your facility safety audit, one

Health & Safety Program, Safety Culture, Incentives

Job Hazard Analysis, Including Ergonomic Assessment

Job Hazard Analyses: The Experts Speak

“As part of a large corporation, I had the time and resources to

The steps involved in a JHA are as follows:

Figuring Out a Solution Prioritize Your Findings

Document & Store Your Audit Results

Ready to improve safety?

True (Non)-Safety Stories

I-beam Strikes Worker

Explosion Kills Experienced Worker

Following an inspection, OSHA issued citations for two

• Frequent and regular inspections of equipment were

Live Overhead Lighting Kills Electrician

DuraTagTM LO/TO Tag Stock - Implementing a lockout/

Visual Communication Inspection

As you conduct your facility safety inspection or audit,

Type of label Description

HazCom 2012 (OSHA req.), GHS (international standard)

Use OSHA & ANSI compliant safety signs to warn against

employees and staying compliant. Forklift area

NFPA compliant labels describe health risk, flammability, and volatility

Use premium vinyl, high-tack, oily-surface, extreme temperature,

Flexible, printable, photoluminescent, and non-skid floor marking tapes

11 877.534.5157 | GraphicProducts.com

DON’T TAKE CHANCES

13 877.534.5157 | GraphicProducts.com

Top 1O OSHA Violations for 2O16

2015 2014 2013

2. Hazard communication: Poor labeling, lack of training, insufficient safety data

3. Scaffolding: Unsecured planks, not level, no guardrails, etc. 3 3 3

4. Respiratory protection: Poorly fitting respirators, improper storage and cleaning 4 4 4

5. Lockout/tagout: Insufficient LO/TO safety program, lack of tagging, unclear

7. Ladders: Improper storage and use of ladders 7 7 7

8. Machine Guarding: Pinch points, missing guards, etc. 9 9 10

9. Electrical, Wiring Methods: Unsafe equipment or installation, environment, work

• When apparent imminent danger, to enable the employer Right to Inspect

Get a detailed look at OSHA’s Top 1O violations for

Tips for Communicating with Your Compliance Officer

A pre-designated representative of the employer should

You can always take a “time out.” If the representative is

1. OSHA & ANSI Z535—Compliant Safety Signs

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: ________________________________ Due date: _

Person responsible: _________________________________ Due date: _

Person responsible: _________________________________ Due date: _