What OSHA Inspectors Look for During a Surprise Inspection
OSHA inspections are rarely scheduled in advance, and when an inspector arrives unannounced, businesses must be prepared to demonstrate compliance at a moment’s notice. Whether it’s a routine check, a complaint investigation, or a response to a workplace incident, OSHA inspectors focus on key areas to determine if a business is meeting federal safety standards. Below are the main things OSHA inspectors look for during a surprise inspection—and how business owners can prepare to avoid costly penalties.
1. General Workplace Safety Practices
Inspectors assess overall workplace safety, identifying hazards that could result in injuries, illnesses, or fatalities.
They look for cluttered workspaces, blocked emergency exits, fire hazards, and improper equipment storage.
Employees should be trained to follow safety procedures, and documentation should be readily available.
2. Personal Protective Equipment (PPE) Compliance
OSHA inspectors check whether employees are wearing required PPE for their job duties.
Common PPE violations include lack of gloves, respirators, safety goggles, hard hats, and steel-toe boots.
PPE must be in good condition, fit properly, and be used consistently where required.
3. Machine Guarding and Equipment Safety
Machinery must have proper guards and safety mechanisms to prevent injuries.
Inspectors assess whether lockout/tagout (LOTO) procedures are in place to prevent accidental machine startups.
Electrical panels, conveyors, and other equipment must meet OSHA safety standards.
4. Hazard Communication and Chemical Handling
Businesses must have Safety Data Sheets (SDS) for all hazardous substances, including cleaning chemicals and industrial solvents.
Employees should know how to handle, store, and dispose of hazardous materials safely.
Inspectors also check for proper labeling of hazardous chemicals and emergency procedures for spills.
5. Fall Protection and Ladder Safety
OSHA requires guardrails, harnesses, or other fall prevention measures for employees working at heights.
Ladders and scaffolding must be properly secured, regularly inspected, and used correctly.
Flooring and walking surfaces must be clear of obstructions and hazards to prevent slips and falls.
6. Emergency Preparedness and Exit Routes
Inspectors verify that businesses have clear emergency exits, proper signage, and accessible escape routes.
Fire extinguishers, sprinklers, and emergency eyewash stations must be maintained and readily available.
Employers must have evacuation plans and conduct safety drills as needed.
7. Air Quality and Respiratory Protection
OSHA assesses whether businesses monitor airborne contaminants, dust, and toxic fumes that could pose health risks.
Work areas that require respirators or ventilation systems must meet specific compliance standards.
Inspectors may conduct air sampling tests to ensure workplace air quality meets OSHA regulations.
8. Recordkeeping and Documentation
Businesses are required to maintain OSHA 300 logs, documenting injuries, illnesses, and workplace incidents.
Inspectors review employee safety training records, inspection reports, and certifications.
Missing or incomplete documentation can result in fines—even if no hazards are present.
9. Employee Interviews and Compliance Verification
OSHA inspectors may privately interview employees about workplace conditions.
Questions often focus on safety training, hazard reporting, and compliance with company policies.
Employees should feel comfortable answering truthfully without fear of retaliation.
10. Corrective Actions for Previous Violations
If a business was cited in a previous OSHA inspection, the inspector will check whether corrective actions have been fully implemented.
Failure to address prior violations may result in increased penalties.
Maintaining ongoing compliance is crucial for businesses with past citations.
How to Prepare for an OSHA Inspection
OSHA fines can range from $16,131 per violation to $161,323 for repeat offenses, making proactive compliance essential. Businesses can avoid penalties and workplace disruptions by:
Conducting mock OSHA audits to identify compliance gaps before an official inspection.
Providing regular safety training to employees.
Keeping documentation and workplace hazard assessments up to date.
Working with risk management experts to implement OSHA-compliant protocols.
Schedule a Mock OSHA Inspection Today
At Paravel Risk Management, we help businesses prepare for OSHA inspections with mock audits, compliance training, and hazard assessments. Don’t wait until an inspector shows up unannounced—protect your business today!
For more information or to schedule a Mock OSHA Inspection, contact Nathan Fredrickson at 605-759-8778 or nate@paravelrm.com.