Graphic Products, a company that provides safety and visual communication solutions, has pulled together a list of OSHA’s Top 10 Safety Violations for 2015. Although the data indicates that the total number of incidents were down 4.5% from 2014 and 11% from 2013, preventable deaths and workplace accidents continue to occur for the same reasons:

  1. Fall Protection: 7,402 citations (1926.501) – OSHA’s most-cited violation for the fifth year running.
  2. Hazard Communication: 5,681 citations (1910.1200) – The second-most cited violation for the fourth year running, though HazCom chemical labeling rules may have contributed to an overall decline of nearly 20%.
  3. Scaffolding: 4,681 citations (1926.451) – Despite a 6% decrease from 2014, scaffolding accidents remained the third-most cited violation. Protecting workers from scaffold-related accidents would eliminate 4,500 injuries and 35-50 deaths every year.
  4. Respiratory Protection: 3,626 citations (1910.134) – An estimated 5 million workers are required to wear respirators in 1.3 million U.S. workplaces.
  5. Lockout/Tagout: 3,308 citations (1910.147) – Approximately 3 million workers are at risk each day if LO/TO is not properly implemented.
  6. Powered Industrial Trucks: 3,004 citations (1910.178) – Powered industrial trucks fall over, hit and crush people, or start up inadvertently, causing accident or death.
  7. Ladders: 2,732 citations (1926.1053) – Used throughout plants and warehouses, falls from ladders are often involved in occupational fatalities.
  8. Electrical–Wiring Methods: 2,624 citations (1910.305) – Most electrical accidents result from unsafe equipment, unsafe environments, or unsafe work practices.
  9. Machine Guarding: 2,540 citations (1910.212) – Moving machine parts have the potential to cause severe workplace injuries, such as crushed fingers or hands, amputations, burns, or blindness.
  10. Electrical-General Requirements: 2,181 citations (1910.303) – Electrical hazards are the second-leading cause of death in the construction industry, killing an average of 143 construction workers each year, according to The Center for Construction Research and Training.


Many manufacturing facilities are experiencing a skilled workers shortage. A survey conducted by Deloitte and the Manufacturing Institute stated that 67% of respondents indicated a moderate to severe shortage of available qualified workers, with 56% anticipating a worsening shortage over the next three to five years. Moreover, those percentages climb to 83% and 76% for skilled production positions.

These declines don’t stop business from running or the need to stay competitive. Manufacturers are working to stay competitive in today’s changing market place by actively participating in the development and training of skilled production workers. To do so, they are collaborating with training partners to develop training programs and curriculums to meet their needs.

The main question to training managers is whether or not you need your team to be familiar or proficient with what they are going to be trained on.

When it comes to safety procedures and working on electrical equipment, Simutech’s Troubleshooting Skills Training System™ allows users to learn a systematic approach to electrical troubleshooting, safe work methods and most importantly, a safe, simulated environment in which to master these skills.

The Financial Costs of Electrical Accidents

Beyond the safety violations that affect work environments, there is also the financial impact of these violations as well as financial repercussions in regard to the accidents.

For example, a study conducted by Mission Critical indicated that the average electrical accident costs in and around $750. However, the National Safety Council states that work-related injuries can cost business more than $30M in fines, medical costs, litigation, lost business and equipment costs.

Just considering the potential downtime costs is astronomically more expensive than investing in corporate training. The following are downtime costs estimates taken from the State University of New Jersey Rutgers Industrial Productivity Training Manual Version 2.0, 2006:

Downtime Cost Estimates

Forest Products $7,000 per hour
Food Processing $30,000 per hour
Petroleum / Chemical $87,000 per hour
Metal Casting $100,000 per hour
Automotive $200,000 per hour

Companies have the ability to greatly reduce the number of annual safety violations, especially when it comes to lockout/tagout citations, electrical-wiring methods and electrical-general requirements citations simply through training and practice.

Simutech’s Troubleshooting Skills Training System offers a systematic approach to electrical troubleshooting and ensures users adopt safe operating procedures when working in its simulation- based environment. Download a demo today, and let us know what you think.

BONUS! Graphic Products developed an infographic on OSHA’s Top Ten Safety Violations – download it today!

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