OSHA Can’t Inspect Every Workplace: How It Chooses Which Ones to Target

Every year, OSHA (the Occupational Safety and Health Administration) is responsible for protecting the safety of over 130 million workers across millions of workplaces in the United States. But with limited staff and resources, it’s simply impossible for OSHA to inspect every single worksite.

So how does OSHA decide which workplaces to inspect first?

Let’s take a closer look at how OSHA targets inspections — and what that means for employers and employees alike.

⚖️ Why OSHA Can’t Inspect Every Workplace

There are more than 10 million workplaces under OSHA’s jurisdiction, yet only a few thousand OSHA compliance officers across the country. That means OSHA must be strategic — focusing on the most serious hazards and highest-risk industries to make the biggest impact on worker safety.

Instead of random inspections, OSHA uses a targeted approach based on potential danger, severity of hazards, and history of violations.

🎯 OSHA’s Inspection Priorities

OSHA organizes its inspections by priority levels, ensuring that the most dangerous situations are addressed first.

1. Imminent Danger Situations

Top priority goes to any situation where an OSHA officer believes death or serious physical harm is likely to occur immediately.Examples include:

• A confined space with toxic gas and workers inside

• Unprotected workers exposed to high-voltage lines

• Leaking chemical vessels or pressure systems

When an imminent danger is reported, OSHA acts quickly — often inspecting within hours.

2. Fatalities and Catastrophes

Next in line are incidents involving:

• A fatality

• The hospitalization of one or more employees

• Amputation or loss of an eye

Employers are required to report these incidents within 8 hours (for fatalities) and within 24 hours for other serious events.

OSHA will often inspect the scene to determine if violations contributed to the incident.

3. Complaints and Referrals

When workers or their representatives file a safety complaint, OSHA takes notice. Complaints that allege serious hazards or violations of OSHA standards can trigger an inspection.

Referrals also come from:

• Other government agencies (like EPA or NIOSH)

• Media reports

• Local fire departments or law enforcement

Employee complaints play a vital role in helping OSHA identify unsafe workplaces that might otherwise go unnoticed.

4. Programmed Inspections

These are planned inspections targeting industries, workplaces, or operations that have high rates of injuries, illnesses, or serious hazards.

Common industries include:

• Chemical manufacturing and refining

• Construction

• Shipbuilding and maritime

• Warehousing and logistics

OSHA uses data from injury and illness reports (OSHA 300 logs, DART rates, etc.) to focus on sites with elevated risk levels.

5. Follow-Up Inspections

If a company has already been cited for safety violations, OSHA may return to ensure the issues have been corrected.These inspections are crucial for verifying compliance and accountability.

🧱 Targeted Emphasis Programs

Beyond its general priorities, OSHA also runs National and Regional Emphasis Programs (NEPs/REPs) — specialized campaigns focusing on particular hazards or industries.

Examples include:

• Process Safety Management (PSM) for chemical facilities

• Heat Stress Prevention

• Respirable Crystalline Silica

• Amputation Hazards in Manufacturing

These programs allow OSHA to target inspections where emerging or ongoing hazards are most likely to occur.

🧰 What This Means for Employers

Even if your facility has never been inspected, OSHA’s data-driven targeting means no workplace is off the radar.

Employers should:

• Conduct regular self-inspections and audits

• Correct hazards immediately when discovered

• Maintain accurate OSHA logs (300, 300A, and 301 forms)

• Train employees on recognizing and reporting hazards

• Document all safety actions and improvements

Preparation not only keeps workers safe but also demonstrates a proactive safety culture — something OSHA values when evaluating compliance.

💡 The Bottom Line

OSHA can’t be everywhere at once — but it focuses its efforts where workers face the greatest risks. By targeting high-hazard industries, responding to serious incidents, and following up on credible complaints, OSHA fulfills its mission to keep American workers safe.

For employers, the message is simple:

Don’t wait for OSHA to show up — make safety a daily priority.

🚀 Strengthen Your Safety Program with Chemical Coast Industrial Training

At Chemical Coast Industrial Training, we help companies prepare for OSHA expectations through interactive, scenario-based safety programs. From Process Safety Management to Lockout/Tagout and Permit-to-Work, our training is designed to go beyond compliance and build true safety leadership.

📅 Contact us today to schedule a course or safety consultation and keep your workplace inspection ready.