Every year, OSHA drops a list you don’t want to be on — the Top 10 Most Frequently Cited Workplace Violations. And if you’re in the printing industry, this list is more than just a ranking; it’s a roadmap for improving workplace safety and avoiding costly fines.
For fiscal year 2024 (October 1, 2023 – September 30, 2024), OSHA once again pulled data from across industries. Printing, which falls under "general industry," had its own standout set of violations — and it’s time for a reality check. Whether you’re running a small shop or managing a large printing facility, use this list to audit your own safety practices.
Here is the top 10 violations OSHA found in printing operations this year:
Hazard communication (29 CFR 1910.1200) OSHA’s Hazard Communication Standard (HCS) requires information to be communicated to employees about the chemical hazards they are exposed to and protective measures to ensure their health and safety. Common citations include not having a written program, safety data sheets for all chemicals, employee training and secondary container labels.
Lockout/Tagout (29 CFR 1910.147) The lockout/tagout regulation protects employees from unexpected machine startups or hazardous releases during servicing and maintenance. Failing to lockout equipment, have a written program and conduct annual inspections of machine-specific procedures are the most common violations.
Respiratory protection (29 CFR 1910.134) Failing to establish a written respiratory program was one of last year’s most common violations, followed by the failure to provide proper medical evaluations to those using respirators. Voluntary use of dust masks, N-95 respirators, and elastomeric respirators (e.g. the ones with cartridges) requires that employees be given a copy of Appendix D of the standard. Those using elastomeric respirators also require a partial written program that addresses medical evaluation and care and use of respirators and a medical evaluation.
Machine guarding (29 CFR 1910.212) OSHA has several standards to protect employees from exposure to hazards such as, ingoing nip points, points of operation, flying sparks and chips, and other moving components. This regulation requires that physical guards be provided to protect employees from exposure and contact with the hazards associated with moving parts.
Personal protective equipment (29 CFR 1910.132) OSHA requires all employers to conduct a formal written workplace hazard assessment to determine what personal protective equipment (PPE) is required to protect employees from injuries. In addition, employers are required to provide PPE and provide employee training in its proper use. Failure to conduct and certify the assessment is a commonly overlooked requirement.
Powered industrial trucks (29 CFR 1910.178) Employees that operate forklifts or other industrial-powered vehicles, such as pallet jacks, must be initially trained, certified, and reevaluated every three years. Safety violations include improper vehicle use, lack of training, and failing to recertify operators every three years.
Electrical safety – general (29 CFR 1910.303) This regulation requires electric equipment to be free from recognized hazards that are likely to cause death or serious physical harm including guarding of live parts. to. The most-cited paragraph covers things like improper installation of an electrical box with the most common being using boxes with “knock outs” as pendant drops, missing breakers in a breaker box, running flexible cords through holes in walls, ceilings, or floors, not using ground fault circuit interrupters, and improperly using power strips. Another common violation is the failure to maintain access and working space around electrical equipment, which is three feet.
Walking and working surfaces - general (29 CFR 1910.22) OSHA’s walking and working surfaces are a broad regulation covering any area where an employee walks, stands, or works. One key requirement is that the workplace must be regularly inspected, maintained, and kept clear of tripping and hazards such as cords on the floor, sharp or protruding objects, loose boards, corrosion, leaks, spills, snow, and ice.
Occupational noise exposure (29 CFR 1910.95) Employers are required to monitor noise levels to identify employees that may be routinely exposed to noise at or above an 8-hour Time-Weighted Average (TWA) of 85 decibels (dB). Employees exposed to this level of noise must be tested annually for hearing loss, provided training every year, and a copy of the standard must be posted in the workplace. Exposures to noise at such as 90 dBA for 8 hours require employees to wear mandatory hearing protection.
Electrical safety - wiring methods, components, and equipment for general use (29 CFR 1910.305) This regulation covers requirements for facility wiring, cabinets, boxes and fittings, switches, conducts, enclosures for damp and wet location, and has many provisions. Among the prohibitions in this regulation is using extension cords for permanent wiring and damaged cords. It also requires breaker identification and labeling, not allowing open slots in breaker boxes, missing knockouts in junction or breaker boxes, and having proper pendant drops for portable equipment.
A Rising Concern: Methylene Chloride
Coming in at number 11 this year is methylene chloride exposure (29 CFR 1910.1052). If you're still using this chemical, which is commonly found in blanket fixes and spotting fluid, be aware that EPA has banned its use in printing starting April 28, 2026. Until then, OSHA requires employee exposure monitoring whenever the chemical is used and if you skip it, that’s an automatic citation. Companies that are using methylene chloride are encouraged to find a replacement for it as soon as practical.
The Top 10
Regarding the other violations for fiscal year 2024, there was a shuffling of the top five. However, the most cited violations tend to remain consistent from year to year. One new regulation on the Top 10 list this year is walking and working surfaces. When OSHA revised the standard in 2017, they significantly expanded the requirements and included fall protection, ladder safety, and general requirements to prevent slips, trips, and falls. This means that any trip hazards such cords or hoses on the floor must be picked up.
The regulations addressing machine safety - lockout/tagout standard and machine guarding remained as some of the most frequently cited standards. These standards are also a priority for OSHA as the printing industry is still considered a high hazard industry for amputations.
Due to the severe injuries associated with equipment, such as amputations, crushing, and broken bones, citations for not meeting lockout/tagout and machine guarding requirements remain common. For lockout/tagout violations, OSHA noted the lack of a written program, energy control procedures, and employee training requirements not being met.
Hazard communication addressing chemical safety remains in the top five of all violations. The most cited violations under the hazard communication standard are the lack of a written program, no employee training, not having Safety Data Sheets (SDS) for all chemicals, and no secondary chemical container labeling.
Penalties Are Steep and Stacking Up
When conducting an inspection, OSHA tends to find multiple violations, and under the current enforcement guidance, field offices are instructed to essentially itemize each violation and assign the maximum penalty. It is OSHA’s position that the penalties are not high enough to provide an incentive for companies to comply with the regulations. Given the serious nature of these violations, the average penalty being imposed on printing operations remains high, ranging from $7,000-$10,000 for each violation. The highest penalty that can be imposed for a violation is $16,500. In the case of a repeat or willful violation, however, the maximum penalty can reach $165,514 for each violation.
Even though OSHA can reduce penalties for small businesses, many citations for printing operations will start with a total penalty range of $40,000-$45,000 and can be much higher for larger printing operations.
Use the List to Your Advantage
The Top 10 list isn’t just a warning, it is a guide. Many of these violations are repeat offenders year after year, meaning OSHA will be looking closely at all of them. If your safety program covers these areas thoroughly, you are already ahead of the curve.
If not, take action. Review your programs, retrain your teams, and fix those that are not compliant. Safety isn’t just about avoiding fines it is about protecting your team and your business.
The Alliance’s Government Affairs Department has many resources including written program templates for lockout/tagout and hazard communication designed to assist printing operations and their compliance programs. The iLEARNING+ platform provides a new training course on machine guarding, lockout/tagout, and hazard communication. Please contact Gary Jones at gjones@printing.org or Sara Osorio at sosorio@printing.org for assistance.
In this article, Gary Jones, VP of EHS Affairs, PRINTING United Alliance, addresses OSHA compliance. More information about OSHA can be found at Business Excellence-EHS Affairs or reach out to Gary should you have additional questions specific to how these issues may affect your business: gjones@printing.org.
To become a member of the Alliance and learn more about how our subject matter experts can assist your company with services and resources such as those mentioned in this article, please contact the Alliance membership team: 888-385-3588 / membership@printing.org.