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Industrial Safety Guide

An OSHA-aligned reference for factory and industrial facility floors. Review the Do's and Don'ts by safety category, then explore the IPS products built to help you meet each standard.

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2.6M
Non-fatal injuries reported annually in U.S. manufacturing
$170B
Annual cost of workplace injuries to U.S. employers
~70%
Of injuries preventable with proper guarding and procedures
#1
Machine guarding is the most cited OSHA standard in manufacturing

This guide covers the safety categories OSHA most frequently cites in general industry inspections. Each tab presents what your facility must do, and what to avoid, organized by standard. Below the guide you will find the IPS products built to support compliance in each area. Download the PDF for a printable reference suited for training sessions and floor posting.

OSHA Safety Reference

Do's and Don'ts by Safety Category

29 CFR 1910.212 / 1910.217 / ANSI/RIA R15.06   Machine guarding is the most cited OSHA violation in manufacturing. Every point of operation, power transmission component, and rotating part must be guarded.

Do
  • Guard all points of operation, power transmission components, and rotating parts
  • Use fixed guards wherever possible; use interlocked guards where routine access is needed
  • Install light curtains and safety sensors on automated equipment and robot cells
  • Inspect guards at the start of every shift and document findings
  • Follow ANSI/RIA R15.06 for robotic cell safety guarding design
  • Post "Do Not Remove Guard" signage on all guarded machines
Don't
  • Never operate machinery with guards removed or bypassed
  • Don't reach into a machine's point of operation before locking out first
  • Don't use improvised guards made from cardboard, tape, or zip ties
  • Don't defeat interlocks or safety sensors under any circumstances
  • Don't modify guard openings beyond manufacturer specifications
  • Don't allow unauthorized personnel inside robot work envelopes

29 CFR 1910.212 / ANSI/RIA R15.06 / ISO 10218   Full enclosures are the highest level of physical guarding for robot cells, machining centers, and optical or laser processes. Interlocked access doors are required wherever workers need entry.

Do
  • Fully enclose automated and robotic systems whenever feasible
  • Integrate interlocked access doors so motion stops before entry is possible
  • Use polycarbonate or mesh panels to maintain visibility into the cell
  • Design enclosures with dedicated, labeled maintenance access points
  • Include ventilation or sound-insulation panels where process hazards require it
  • Label all enclosure entry points with hazard signage and access procedures
Don't
  • Don't allow personnel to enter an enclosure while the machine is energized
  • Don't bypass door interlock sensors to speed up production
  • Don't assume guarding is intact when panels are missing or damaged
  • Don't use enclosures as a substitute for proper LOTO procedures
  • Don't block enclosure ventilation openings
  • Don't allow unauthorized modifications to enclosure structure or panels

OSHA General Duty Clause Section 5(a)(1) / NIOSH Lifting Equation   Musculoskeletal disorders account for roughly 30% of all worker injury and illness cases in manufacturing. Ergonomic workstation design is one of the highest-return safety investments a facility can make.

Do
  • Conduct ergonomic assessments at every workstation and act on findings
  • Provide height-adjustable workstations that accommodate workers of all sizes
  • Position tools and materials within the worker's primary reach zone
  • Use anti-fatigue mats and padded edges at all standing positions
  • Implement job rotation to reduce repetitive motion exposure
  • Use mechanical assists for loads over 50 lbs
  • Train employees on proper lifting technique and document it
Don't
  • Don't require sustained awkward postures such as bent wrists, twisted trunk, or overhead reach
  • Don't ignore early musculoskeletal disorder symptoms; early action prevents lost-time injuries
  • Don't set production quotas that force workers to sacrifice safe technique for speed
  • Don't overlook footwear; poor support accelerates fatigue and injury
  • Don't use high-vibration tools without anti-vibration controls in place
  • Don't place heavy items above shoulder height or below knee height

29 CFR 1910.147 / Control of Hazardous Energy   Failure to control hazardous energy causes approximately 50,000 injuries and 120 fatalities each year. A written LOTO program with trained personnel and proper hardware is non-negotiable in any industrial facility.

Do
  • Develop a written LOTO program with machine-specific procedures for every piece of equipment
  • Train all authorized and affected employees annually and document attendance
  • Apply your personal lock before any service or maintenance task
  • Verify zero energy state by testing with a meter and attempting to start the machine
  • Account for all energy sources including electrical, hydraulic, pneumatic, gravity, thermal, and chemical
  • Conduct LOTO program audits at least once per year
Don't
  • Never rely on tagout alone when lockout is feasible; tags are warnings, not locks
  • Never remove another worker's personal lock under any circumstances
  • Don't skip LOTO because a task "only takes a minute"
  • Don't assume de-energized because the power switch is off; verify independently
  • Don't overlook stored energy such as charged capacitors, springs, and pressurized lines
  • Don't allow unqualified personnel to perform LOTO procedures

29 CFR 1910.22 / Walking-Working Surfaces   29 CFR 1910.141 / Sanitation   Slips, trips, and falls are the second leading cause of workplace fatalities. The 5S methodology provides a structured framework for maintaining a safe, organized floor at all times.

Do
  • Keep all aisles, exits, and emergency equipment routes clear at all times
  • Clean up spills immediately and post wet-floor signage
  • Use floor tape to define walkways, hazard zones, and storage areas
  • Implement and document a daily 5S routine
  • Ensure walking surfaces are non-slip; use anti-fatigue matting at standing workstations
  • Route cables and hoses off walking surfaces using proper management hardware
Don't
  • Don't block fire exits, extinguishers, electrical panels, or emergency stops
  • Don't allow scrap, waste, or excess inventory to accumulate on the floor
  • Don't ignore damaged flooring, broken grates, or uneven walking surfaces
  • Don't run cables across walkways without proper management hardware
  • Don't neglect the area under and around conveyors, workstations, and machines
  • Don't store materials above safe load limits in overhead areas

29 CFR 1910.303-333 / NFPA 70E Arc Flash Standard   Electrical hazards cause more than 300 fatalities and 4,000 injuries in U.S. workplaces each year. Qualified workers, arc flash analysis, and strict access controls are the foundation of electrical safety.

Do
  • Allow only qualified electricians to perform electrical work
  • Complete an arc flash hazard analysis and label all electrical panels accordingly
  • Use GFCI protection on all 120V outlets in wet or damp locations
  • Inspect power cords, extension cords, and plugs regularly for damage
  • Maintain 36 inches of clear working space in front of all electrical panels
  • Follow NFPA 70E for arc flash PPE selection when energized work is unavoidable
  • Ground all electrical equipment and verify grounding before use
Don't
  • Never perform energized electrical work unless de-energizing creates a greater hazard
  • Don't use extension cords as a permanent wiring solution
  • Don't overload outlets, circuits, or extension cords beyond rated capacity
  • Don't store materials in front of or on top of electrical panels
  • Don't use damaged cords; remove from service and tag out immediately
  • Don't allow unqualified personnel near open electrical panels
  • Don't bypass or defeat overcurrent protection devices

29 CFR 1910.155-165 / Fire Protection   29 CFR 1910.38 / Emergency Action Plans   A written Emergency Action Plan is required for all facilities with more than 10 employees. Unobstructed egress, proper flammable storage, and regular drills are the cornerstones of fire prevention.

Do
  • Maintain a written Emergency Action Plan and review it with all employees annually
  • Conduct fire drills at least once per year and document participation
  • Inspect fire extinguishers monthly; certify annually by a licensed contractor
  • Maintain 18 inches of clearance below all sprinkler heads at all times
  • Store flammable liquids in approved FM/UL-listed flammable storage cabinets
  • Post evacuation routes and assembly points prominently at all exits
  • Designate and train fire wardens for each area of the facility
Don't
  • Don't block fire exits, fire extinguishers, or sprinkler control valves
  • Don't prop fire doors open; they exist to contain fire and smoke
  • Don't allow combustible materials such as oily rags, cardboard, or packaging to accumulate
  • Don't perform hot work without a hot-work permit in place
  • Don't disable smoke detectors, suppression systems, or alarm panels
  • Don't assume employees know the EAP without regular drills
  • Don't store flammables in unapproved containers or locations

29 CFR 1910.178 / Powered Industrial Trucks   Powered industrial trucks are involved in approximately 85 fatal workplace incidents annually. Separating pedestrian and forklift traffic is the single most effective prevention measure.

Do
  • Train and certify all forklift operators before unsupervised operation
  • Conduct and document pre-shift inspections on every powered industrial truck
  • Clearly mark forklift lanes and pedestrian walkways with floor tape and signage
  • Slow down and sound the horn at all blind intersections and building entrances
  • Travel with loads low at 6 to 10 inches and mast tilted back for stability
  • Remove forklifts from service immediately when defects are found
  • Recertify operators every 3 years or after any incident
Don't
  • Never allow untrained personnel to operate powered industrial trucks
  • Don't carry passengers on forklifts not designed for it
  • Don't exceed rated load capacity or travel with elevated loads
  • Don't exceed 5 mph in facility aisles or 3 mph near pedestrian areas
  • Don't use forklifts to lift workers without an OSHA-approved work platform
  • Don't leave a running forklift unattended
  • Don't turn on ramps or inclines when carrying a load

29 CFR 1910.1200 / Hazard Communication / GHS Revision 7   HazCom violations appear consistently in OSHA's annual top-10 citation list. Every worker must understand the chemical hazards they work with, on every shift.

Do
  • Maintain a current Safety Data Sheet for every hazardous chemical on site
  • Make SDS access available to all employees on all shifts by binder or electronic means
  • Ensure all containers are labeled with product name, GHS pictograms, and signal word
  • Train all employees on GHS label elements and how to read an SDS
  • Include chemical hazards in your written Hazard Communication Program
  • Conduct HazCom refresher training when new chemicals are introduced
  • Post emergency response information near all chemical use and storage areas
Don't
  • Never transfer chemicals into unlabeled or improperly labeled containers
  • Don't allow SDS documents to become outdated; update within 3 months of any revision
  • Don't mix chemicals without verifying compatibility on the SDS first
  • Don't store incompatible chemicals near each other such as acids near bases or oxidizers near flammables
  • Don't dispose of chemicals down drains; follow local environmental regulations
  • Don't skip HazCom training for seasonal, contract, or temporary workers

Download the Full Safety Reference Guide (PDF)

Printable OSHA-specific Do's and Don'ts for all 9 categories. Ideal for training, toolbox talks, and floor posting.

Download PDF
IPS Safety Guarding Solutions

Products Built for OSHA Machine Guarding Compliance

Panel Connection Options

Angle brackets, safety hangers, and hinges that keep barrier systems rigid, supported, and safely accessible for maintenance.

Safety Hanger

Safety Hangers

Suspend cables and overhead panels. One-handed operation, corrosion resistant, reduces tripping hazards.

Angle Bracket

Angle Brackets

Join sections at any angle. High-strength aluminum, no welding, quick to assemble and adjust.

Hinge

Hinges

Create secure access points for maintenance without compromising barrier integrity.

Post Options

Corner and middle posts that provide structural integrity at every junction and mid-span point in a safety barrier system.

Corner Post

Corner Posts

Absorb impact at barrier junctions, prevent dislodgement, customizable to any layout.

Middle Post

Middle Posts

Support long barrier runs, prevent sagging, maintain protective integrity under stress.

Panel Options

Single, double, door, and standard extrusion panels in PVC mesh, corrugated steel, polycarbonate, ACM, and solid plastic.

Single Panel

Single Panel

PVC or corrugated steel mesh. 4x8 ft sections, 1/2 inch and 1 inch mesh options.

Double Panel

Double Panel

Dual-layer construction for added impact resistance or noise reduction.

Safety Door

Safety Door

Clamp-profile hinged door for controlled, secure maintenance and emergency access.

Standard Panel

Standard Panel

Plastic, ACM, polycarbonate, or steel mesh secured with gasket strip or push-in panel seal.

Add-Ons and Accessories

Safety sensors, light curtains, and GuardLink taps integrate with guarding systems to detect human presence, stop hazardous motion, and enable networked safety diagnostics across the facility.

SensaGuard

SensaGuard Interlock Switches

RFID non-contact interlock from Rockwell Automation. Large sensing range, tolerant to misalignment. Stops machine motion before a guarded door can be opened. Supports 29 CFR 1910.147 LOTO requirements.

Light Curtain

Light Curtains

Infrared presence detection without a physical barrier. Nine lengths from 320mm to 1600mm. Ideal for robot cells and conveyor entry points where workers need regular access.

GuardLink Tap

GuardLink Taps

Connect GuardLink safety devices via quick-connect M12 cables. Enables networked safety diagnostics, reduces wiring complexity, and supports system-wide monitoring across large installations.

Need help specifying the right guarding system? IPS engineers provide no-cost design support with every order.

View Full Safety Guarding Line Machine Enclosures Ergonomic Workstations

IPS Offers No-Cost Engineering Support

Whether you need a safety guarding system for a new robot cell, ergonomic workstations for an assembly line, or machine enclosures for a machining center, IPS engineers work with you from start to finish. Complimentary engineering is included with every order.

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This guide is provided by Industrial Profile Systems for informational purposes only and does not constitute legal or compliance advice. Always consult current OSHA standards at osha.gov and a qualified safety professional for guidance specific to your facility. © 2025 Industrial Profile Systems  ·  industrialprofile.com