OSHA’s Top 10 Most-Cited Violations in 2025: What Manufacturing Shops Still Get Wrong (and How to Fix It Fast)
- Aug 6
- 6 min read
Fall protection has held the #1 spot for the 15th year running. That’s no surprise if you’ve walked the shop floor lately. The same hazards keep popping up, and the same mistakes keep costing time, money, and sometimes worse. But what do the final 2025 numbers really mean for your plant? Where should you focus your safety efforts to keep your crew safe and your operation humming?
According to final Fiscal Year 2025 data released by OSHA and detailed by Safety+Health Magazine on April 29, 2026 (OSHA Information System data covering October 1, 2024 – September 30, 2025, pulled April 15, 2026). The ranking order matches the official list currently published on osha.gov.
This list is pure gold for manufacturers. It shows exactly where OSHA is looking and where real injuries still happen. If you run a CNC shop, fabrication cell, machining bay, or assembly line, these are the trouble spots that can trip you up. Let’s break down the top 10 violations, why they keep happening, and what you can do this week to fix them.
1. Fall Protection – General Requirements (1926.501) – 6,992 Violations
Fall protection tops the list again, with nearly 7,000 violations. In manufacturing, this usually means workers on elevated platforms, mezzanines, or loading docks without proper guardrails or harnesses. It’s easy to overlook when the job seems routine, but a slip or trip from height can be deadly.
Why it still happens:
Shops often skip installing or maintaining guardrails during quick changeovers or rush jobs. Sometimes, harnesses are available but not inspected or used correctly. Training gaps mean workers don’t always recognize fall hazards in their work cell.
Fix it fast:
Walk your elevated work areas this week and check guardrails, toe boards, and anchor points. Fix or flag anything loose or missing.
Run a quick refresher on fall protection gear use and inspection with your crew. Make it part of your daily toolbox talk.
Update your fall protection plan and post it visibly near elevated work zones.
2. Hazard Communication (1910.1200) – 3,010 Violations
Hazard communication violations often come from missing or outdated Safety Data Sheets (SDS), unlabeled chemical containers, or lack of employee training on chemical hazards. In shops using coolants, solvents, or welding gases, this is a big deal.
Why it still happens:
SDS binders get stuffed in a corner or not updated when new chemicals arrive. Labels fade or get swapped during busy shifts. Training sometimes falls through the cracks, especially with temp or new hires.
Fix it fast:
Audit your SDS binder and chemical labels this week. Replace any faded or missing labels immediately.
Schedule a short hazard communication refresher for your team, focusing on chemicals they handle daily.
Assign a point person to keep the SDS binder current and accessible in every work cell.
3. Ladders (1926.1053) – 2,842 Violations
Ladders are everywhere in manufacturing—from reaching high shelves to machine maintenance. But improper ladder use or damaged ladders cause thousands of citations.
Why it still happens:
Workers often grab the nearest ladder without checking its condition or suitability. Ladders get left damaged or stored improperly. Training on ladder safety is sometimes overlooked in fast-paced shops.
Fix it fast:
Inspect all ladders on site this week. Tag out any with cracks, missing feet, or bent rungs.
Remind your crew about ladder basics: three points of contact, proper angle, and never standing on the top step.
Store ladders in a dry, secure spot to prevent damage and easy access.
4. Lockout/Tagout (1910.147) – 2,562 Violations
Lockout/Tagout (LOTO) violations remain a top concern, especially around presses, mills, and CNC machines. Failure to properly isolate energy sources during maintenance can cause serious injuries.
Why it still happens:
LOTO procedures get skipped during quick fixes or when multiple energy sources are involved. Sometimes, locks or tags are missing or not used correctly. Training gaps and poor documentation add to the risk.
Fix it fast:
Review your LOTO procedures this week. Make sure every energy source is identified and accounted for.
Conduct a hands-on LOTO refresher with your maintenance and machine operators. Use our LOTO checklist resource to cover all bases.
Keep a well-stocked supply of locks and tags in every maintenance area.
5. Respiratory Protection (1910.134) – 2,294 Violations
Respiratory protection is critical in shops dealing with welding fumes, dust, or chemical vapors. Violations often come from missing fit tests, improper mask use, or lack of training.
Why it still happens:
Respirators aren’t always worn correctly or consistently. Fit tests may be overdue or skipped. Workers sometimes don’t understand the hazards or how to maintain their gear.
Fix it fast:
Schedule fit tests for all employees who use respirators this week.
Check that respirators are clean, stored properly, and replaced as needed.
Run a quick training session on when and how to use respiratory protection on the shop floor.
6. Scaffolding (1926.451) – 2,286 Violations
Scaffolding issues pop up in fabrication shops and maintenance areas where temporary platforms are used. Missing guardrails, unstable setups, or improper access cause citations.
Why it still happens:
Scaffolds get assembled by untrained workers or rushed to meet deadlines. Inspections are skipped or incomplete. Sometimes, workers use scaffolds for unintended tasks.
Fix it fast:
Inspect all scaffolding before use this week. Check for guardrails, planking, and secure footing.
Only allow trained personnel to erect or modify scaffolds.
Post scaffold load limits and access rules clearly.
7. Fall Protection – Training Requirements (1926.503) – 2,216 Violations
Even when fall protection gear is available, lack of proper training leads to violations. Workers need to know how to use harnesses, lanyards, and anchors correctly.
Why it still happens:
Training is often a one-and-done event or skipped during busy periods. New hires or temporary workers may miss fall protection training entirely.
Fix it fast:
Schedule regular fall protection training sessions, including hands-on gear demos.
Track training completion and refreshers in your safety management system.
Encourage supervisors to spot-check fall protection use and coach workers on the spot.
8. Powered Industrial Trucks (1910.178) – 2,150 Violations
Forklift and other powered industrial truck violations often involve untrained operators, poor maintenance, or unsafe driving practices.
Why it still happens:
Operators sometimes skip refresher training or use trucks they’re not certified for. Maintenance schedules get pushed back. Unsafe habits like speeding or improper stacking persist.
Fix it fast:
Verify operator certifications and schedule refresher training this week.
Check maintenance logs and inspect trucks for obvious issues before shifts.
Reinforce safe driving rules during daily pre-shift meetings.
9. Eye and Face Protection (1926.102) – 1,965 Violations
Eye and face protection violations happen when workers skip goggles or face shields during grinding, welding, or chemical handling.
Why it still happens:
Workers find PPE uncomfortable or inconvenient. Supervisors may not enforce rules consistently. Sometimes, the right protection isn’t available or replaced when damaged.
Fix it fast:
Check PPE supplies and replace worn or missing eye and face protection gear.
Remind your team why protection matters with real stories or near-miss examples.
Make PPE use a visible part of your safety culture, with supervisors leading by example.
10. Machine Guarding (1910.212) – 1,498 Violations
Machine guarding violations are common around presses, mills, and CNC machines. Missing or damaged guards expose workers to moving parts and pinch points.
Why it still happens:
Guards get removed for quick fixes or adjustments and aren’t replaced. Some machines lack proper guarding by design. Training on hazards and guarding is sometimes weak.
Fix it fast:
Inspect all machine guards this week. Repair or replace any missing or damaged guards immediately.
Train operators on the importance of guards and safe machine operation.
Use our related Insights on machine guarding to update your safety protocols.
Quick-Win Audit: 5-Point Checklist for Your Shop Floor Tomorrow
Check all fall protection gear and elevated work areas. Look for missing guardrails or worn harnesses.
Review your SDS binder and chemical labels. Replace anything outdated or missing.
Inspect ladders and scaffolding. Tag out damaged equipment and ensure proper setup.
Verify LOTO procedures and supplies. Confirm locks, tags, and training are up to date.
Spot-check PPE use and machine guarding. Make sure eye protection is worn and guards are in place.
We’re all in this manufacturing neighborhood together. Keeping people safe and the shop running is a shared goal. What’s working in your facility? What safety headaches keep you up at night? Drop a comment below and share your tips or challenges. Don’t forget to subscribe for more practical manufacturing insights that help you run a safer, smarter shop.
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OSHA’s top 10 manufacturing safety violations in 2025 reveal where shops still slip up — and how you can fix them fast. Check your shop floor today! #ManufacturingSafety #OSHA2025
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