Avoiding OSHA Fines in Manufacturing: Safety Risks and Solutions
Why Workplace Safety is a Business Imperative
Manufacturing remains one of the most hazardous industries in the U.S., with workplace safety violations leading to steep OSHA fines, costly lawsuits, and lost productivity.
According to the Bureau of Labor Statistics (BLS), 395,300 nonfatal injuries were reported in manufacturing in 2023, costing businesses billions in legal fees and lost production. Workplace injuries cost $171 billion annually (NSC, 2023), and fatalities remain high—5,190 workers lost their lives in 2023 (BLS).
Preliminary 2024 OSHA data confirms that manufacturing continues to rank among the most dangerous industries, with frequent violations related to machine guarding, fall protection, and hazardous materials handling.
For manufacturers, workplace safety is not just a compliance issue—it’s a critical business strategy. Failure to adhere to safety regulations can lead to fines, legal risks, employee retention challenges, and severe reputational damage. Below, we break down key enforcement trends, recent OSHA citations, and proven strategies to protect your workforce and bottom line.
Federal Oversight: How OSHA Enforces Workplace Safety
The Occupational Safety and Health Administration (OSHA) sets and enforces safety regulations across industries, and manufacturing consistently ranks among the most-cited sectors for violations. Most employers make a serious effort to maintain workplace safety by providing training and even making safety violations grounds for dismissal. Yet, around 4.6 million workplace injuries occur every year (BLS, 2023).
Recent OSHA Workplace Safety Violations in Manufacturing
OSHA has aggressively fined manufacturers for safety violations, particularly for repeat offenses. Here are some real cases from 2024:
Viscofan USA Inc. (July 2024) – OSHA fined the company $197,000 after two employees suffered severe injuries at its Danville, Illinois facility. Inspectors cited nine repeat and serious violations, including lockout/tagout failures and machine guarding deficiencies, with similar violations reported since 2015.
Dean Sausage Company (December 2024) – Repeated safety violations at its Attalla, Alabama facility resulted in $103,245 in penalties. Between 2022-2023, the company had already paid over $109,823 in OSHA fines, demonstrating a pattern of non-compliance.
These cases highlight that OSHA does not hesitate to impose steep penalties—especially for repeat offenders failing to correct known hazards. Fines can hit $13,653 for serious violations or $161,323 for willful ones (2024), plus legal action costs.
OSHA’s Most Cited Manufacturing Violations (2024)
(Data from OSHA, October 2023–September 2024, released at the NSC Safety Congress & Expo)
Fall Protection – 6,307 violations
Hazard Communication – 2,888 violations
Lockout/Tagout (LOTO) – 2,143 violations
Machine Guarding – 1,874 violations
Respiratory Protection – 2,393 violations
Each of these violations contributes directly to serious injuries, ranging from amputations to chemical exposure-related illnesses—98M lost workdays in 2023 (BLS) prove it.
Legal Risks: Rising Workplace Safety Lawsuits
Beyond OSHA penalties, employee lawsuits related to workplace safety violations are increasing, often resulting in multi-million-dollar settlements.
Lilac Solutions (March 2025) – Former employees sued the company for toxic chemical exposure at its Oakland, California warehouse, alleging that improper ventilation led to serious health risks. The lawsuit also accuses the company of retaliatory firings after safety complaints. (Source: Business Insider, March 2025)
Bay City Ammonia Leak (2024) – Workers at a Texas chemical plant filed a lawsuit after an ammonia leak caused illnesses, citing ignored safety concerns and failures to mitigate risks. Legal costs and settlements could reach millions. (Source: Houston Chronicle, 2024)
These lawsuits illustrate that workplace safety negligence doesn’t just cost fines—it can result in severe legal and reputational consequences. Turnover costs $1T yearly (Gallup), with 52% job-hunting (Gallup, 2024), tank morale and team cohesion—financial losses pile up.
State-Level OSHA Enforcement: Stricter Than Federal Laws?
Some states run their own OSHA-approved workplace safety programs, often imposing stricter penalties than federal OSHA regulations.
2025 Case Study: Illinois Fuel Depot Explosion
In March 2025, a manufacturing facility explosion killed five workers in Illinois. Investigations revealed that cost-cutting measures compromised safety, triggering state and federal OSHA probes. (Source: Reuters, March 2025)
States like California, Michigan, and Oregon have implemented stricter safety laws and higher penalties, making non-compliance even riskier for manufacturers operating in these regions—25% higher fines in California (2024).
For manufacturers, staying compliant means more than just following federal OSHA laws—it requires keeping up with stricter state-level regulations and public image risks.
How to Protect Your Business from OSHA Fines, Lawsuits, and Workplace Injuries
Implement Digital Environmental, Health, and Safety (EHS) Solutions
Case Study: An Asia-based automotive manufacturer deployed an EHS software system at a large U.S. manufacturing site, leading to:
365 hazards identified and resolved in 16 months with hazard checks.
Digitization of site safety inspections and employee reporting for better compliance tracking.
Reduction in manual safety tracking errors, improving audit readiness—75% of firms aren’t ready (OSHA).
(Source: Benchmark Digital Partners LLC, 2023)
By adopting digital safety solutions, manufacturers can proactively identify risks and improve OSHA compliance—productivity spikes.2. Strengthen Employee Safety Training
Companies that implemented certification-based safety training reported a 25% reduction in workplace injuries—safety training cuts risks.3. Hire Safety-Minded Employees
Manufacturers who screen candidates for safety awareness saw 15% lower incident rates—new hires triple injury risk in month one (BLS, 2023)—a safety culture saves.
4. Invest in Proactive Safety Technology
Automated hazard detection systems reduced safety violations by 20% in a 2024 pilot program—winter-ready tech stops $11B in slips (NSC, 2023).
5. Stay Ahead of Regulatory Changes
Businesses that subscribe to OSHA updates and safety alerts avoid up to 70% of common violations—grasp violations and prep or join the 75% failure rate.
Need a Workforce That Prioritizes Safety? We Can Help
Waiting for an OSHA inspection isn’t a safety strategy. Ensuring compliance and worker safety starts with hiring the right people.
At Timpl, we help manufacturers build safety-first workforces by connecting them with highly trained, OSHA-compliant employees.
Reduce the risk of OSHA fines and legal claims
Build a safer, more productive workforce
Improve compliance and worker retention
