In 2009, in California, issues related to the IIPP (Injury and Illness Prevention Program) continued to be the top cause of violations for manufacturing companies. For manufacturers in the period October 2008 to September 2009, there were 397 Cal/OSHA IIPP citations.

The 2009 top 10 Cal/OSHA manufacturing violations are:

1. IIPP – 397 violations. This is the top level document a company must have in California that outlines its safety program. From a Cal/OSHA standpoint, not only must you have an IIPP in place, it must be effective, which includes employee involvement and training.
2. Lockout/Blockout – 316 violations. Any time equipment is being cleaned, maintained, set-up, or adjusted, electrical (lockout) and mechanical (blockout) energy must be controlled to prevent unexpected start-up.
3. Air Tanks – 461 violations. Air tanks, which are pressure vessels, require a permit issued by DOSH (Department of Occupational Safety & Health) to be in operation.
4. Portable Fire Extinguishers – 166 violations. Issues regarding placement, use, maintenance, and testing of portable fire extinguishers provided for use by employees.
5. Electrical Equipment Clearance – 149 violations. Sufficient clearance must be provided around all electrical equipment for safe operation and maintenance.
6. Respiratory Protection – 141 violations. Respirators protect workers against insufficient oxygen environments, harmful dusts, fogs, smokes, mists, gases, vapors, and sprays. Employers need to have a written respiratory protection program and it needs to be part of the company’s IIPP.
7. Control of Hazardous Materials – 128 violations. Employers are required to prevent or minimize the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals.
8. Hazard Communication (HazCom) – 115 violations. Employers must provide information to their employees about the hazardous substances to which they may be exposed. This includes a written hazard communication program, labels and other forms of warning, material safety data sheets (MSDS), information, and training.
9. Emergency Eyewash and Shower Equipment – 113 violations. Eyewash equipment must be provided at all work areas where, during routine operations or foreseeable emergencies, the eyes of an employee may come in contact with a substance that can cause corrosion, severe irritation, permanent tissue damage, or which is toxic by absorption. An emergency shower must be provided at all work areas where, during routine operations or foreseeable emergencies, areas of the body may come in contact with a substance which is corrosive, severely irritating to the skin, or which is toxic by skin absorption.
10. Powered Industrial Truck Operator Training – 103 violations. All employees, prior to operating powered industrial trucks (e.g., forklifts, etc.), must be trained and evaluated by successfully completing a training program.