Case Study: Closing The Safety Gap
- By Justrite Safety Group
- Jul 11, 2025
By partnering with Justrite Safety Group, a major manufacturer in the Southeastern US was able to identify key safety gaps and implement proven solutions to reduce risk, improve compliance, and protect its workforce. They operate a large facility with multiple production lines and a substantial workforce. Like many industrial manufacturers, their operations involve heavy machinery, chemical storage, and frequent material handling-environments where safety risks are ever-present.
Hazard Analysis
Most hazards related to either physical safety (slips, trips, falls), hazardous material handling, or emergency response readiness. A recurring theme was the need for clearer visual cues-signage, matting, and floor marking-to guide safe behavior and restrict access where necessary. The specific hazards identified included:
Hazard |
Environment |
Key Indicators |
|---|---|---|
| Chemical and Flammable Material Storage | Maintenance shop |
Lacking sufficient flammable storage cabinets Safe charging and storage of lithium-ion batteries. |
| Emergency Preparedness | Multiple areas | Missing clearly marked and properly equipped emergency eye wash stations. |
| Slips, Trips, and Falls | Wet or high traffic areas, especially around sinks, welding stations | Absence of anti-slip or anti-fatigue matting. |
| Loading Dock Safety | Loading dock | Better protocols and signage for wheel chock use to prevent vehicle movement during loading and unloading |
| PPE Compliance | Welding and maintenance areas | Gaps in PPE signage and enforcement |
| Traffic and Access Control | Operational areas | Inadequate floor marking and signage contributing to potential congestion and unauthorized access |
VIOLATIONS & RISKS
Identified potential OSHA violations with fines up to $15,625. Some of the top violations found were:
- OSHA 29 CFR 1910.151(c)
- OSHA 29 CFR 1910.178(g)
- OSHA 29 CFR 1910.303(g)(1)
- OSHA 29 CFR 1910.22(a)
Why It Matters
Addressing these hazards isn’t just about compliance, but protecting people and the business. The survey referenced several OSHA and NEC codes, particularly regarding emergency equipment, hazardous material storage, and access to electrical panels. Non-compliance with these regulations can result in significant financial consequences.
Recommendations
By proactively identifying and addressing these risks, facilities like this one can avoid costly incidents, improve employee morale, and maintain uninterrupted operations.
- Improved Emergency Response: Installed and clearly marked emergency eye wash stations with appropriate signage and anti-slip matting.
- Enhanced Hazardous Material Storage: Provided specialized lithium-ion battery charging cabinets and additional flammable storage cabinets.
- Slip and Fatigue Prevention: Deployed anti-slip mats and anti-fatigue mats in areas prone to wetness or prolonged standing, such as by sinks and welding stations.
- Dock Safety Upgrades: Added wheel chocks, dock chains, and warning signage to enforce safe loading and unloading procedures.
- PPE and Access Signage: Installed new PPE requirement signs, "Authorized Personnel Only" signs, and "No Parking" signs to control access and reinforce safety protocols.
- Floor Marking Improvements: Applied high- visibility floor tape and marking shapes to delineate safe walkways, equipment zones, and emergency access areas.
- Operational Best Practices: Introduced janitorial shadow boards to improve organization and reduce trip hazards in production areas.
