If the phrase “OSHA audit” sends a ripple of anxiety through your team, you’re not alone. Most business owners and managers know the importance of workplace safety, but still find inspections stressful — especially when they’re not sure exactly what inspectors are looking for.
Thankfully, safety audits aren’t mysterious. Inspectors don’t walk in hoping to find something wrong. They focus on well-defined areas that, when managed proactively, can help you avoid citations and improve the overall safety and efficiency of your operation.
Let’s walk through what really matters in a safety audit, and how you can set yourself up to pass with confidence.
Start With the Basics
It might seem obvious, but inspectors immediately notice how your facility looks the moment they step inside. Are walkways clear? Are spills cleaned up? Are tools stored properly? A disorganized or cluttered environment sets off alarm bells — not because of aesthetics, but because it signals bigger safety issues may be lurking.
Keeping your workspace clean, orderly, and free of obvious hazards is a low-cost way to make a strong first impression during any safety inspection.
Personal Protective Equipment (PPE): Stocked and Worn
Inspectors pay close attention to PPE. They want to see:
- That your facility has the right gear for the job (gloves, eyewear, hearing protection, etc.)
- That it’s available, accessible, and in good condition
- And most importantly — that it’s actually being worn
Even if you’ve supplied every employee with top-tier PPE, you’ll still be in trouble if someone’s working without it. Make PPE compliance part of your daily culture, not just an audit-day checklist.
Proper Signage and Safety Labels
From chemical storage to high-noise zones, clear and compliant signage is mandatory. Inspectors look for the correct use of hazard communication labels, safety instructions, and warning signs throughout your facility.
This also applies to exits and emergency procedures — e.g. your evacuation routes need to be clearly marked and easy to follow, even in a panic.
Don’t rely on old posters or faded stickers. Signage should be legible, up to date, and placed exactly where it’s needed — and your team should know what each sign means.
Fall Protection and Elevated Work Safety
If your employees work on ladders, scaffolds, platforms, or any elevated surfaces, fall protection is a major inspection focus. OSHA’s fall protection standards are among the most frequently cited — and violations here often come with the steepest fines.
Inspectors want to know:
- Are the right guardrails or harness systems in place?
- Are they being used correctly? (Or are they just for appearances?)
- Has your team been trained on when and how to use them? And, if so, how recent was the last training?
A fall incident is one of the most avoidable — yet dangerous — workplace accidents. Make sure your safety measures are both effective and enforced.
Machine Safeguards
Moving parts, sharp edges, high heat, and fast rotations — these are common hazards in workplaces that use heavy equipment. Inspectors will evaluate whether your machines are properly guarded and maintained.
This includes:
- Physical barriers or guards
- Emergency shutoffs
- Maintenance logs and inspection checklists
If any safeguard is removed — even temporarily — you’re putting your team at risk and opening the door to serious violations. Make sure your team understands that shortcuts around machine safety aren’t acceptable, ever.
Operator Certifications (Especially for Forklifts)
One of the most overlooked issues during safety audits is lack of proof that forklift and powered industrial truck operators are properly certified. (Yes, OSHA requires it. And yes, inspectors will ask.)
If you have even one team member operating a forklift without documentation of certification, your business could face fines, liability issues, and insurance complications. But it’s not just about compliance — it’s about safety. Proper training reduces accidents and gives your employees the confidence they need to operate heavy equipment effectively.
Thankfully, getting certified has never been easier. Online forklift certification programs allow your team to train on their own schedule, from any location, and often at a fraction of the cost of in-person training. These programs typically cover all OSHA requirements, include evaluations, and issue printable certificates that your team can present during inspections.
Emergency Plans, Drills, and Documentation
Even if nothing goes wrong, you still need to prove that you’re prepared for when it does. Inspectors will ask about:
- Fire evacuation plans
- Medical emergency response
- Lockout/tagout procedures
- Incident reporting systems
Don’t just write a plan and let it collect dust. Make sure you’re actively training your team and running drills. The goal is for every employee to know exactly what to do in an emergency — and for your records to reflect that training has taken place.
Internal Audits and Safety Culture
One of the best ways to pass your official safety audit is to run your own first. Conducting internal safety audits like this helps you catch small issues before they become major violations. Involve your team, walk the facility regularly, and document your findings. This shows initiative to inspectors, while also creating a culture of continuous improvement.
Adding it All Up
You shouldn’t have to be scared of your next safety audit. If you plan ahead and know what to do to prepare, you can actually face these audits with confidence. You’ll feel at ease knowing you’re being proactive and purposeful. Good luck!
