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Manufacturing Safety Diagnostic

Your real records plus how your plant actually works. About 20–25 minutes. One site at a time: use that site's own 300A. You get a 0–100 score, a maturity level, red flags and plain next steps.

Your data stays on your device. Everything is calculated in your browser. Nothing you type or upload is sent anywhere. Progress is saved only in this browser so you can come back.

Not a legal or compliance audit. This is a self-assessment for planning. It is not an OSHA inspection, a certification, legal advice, or a prediction of inspection results, and it does not replace a plant walk, a noise survey, exposure monitoring or an arc-flash study. It describes the organization, not individuals. Using it does not create a consulting relationship.

  1. 1 Profile
  2. 2 Records
  3. 3 Programs & training
  4. 4 Culture (42)
  5. 5 Results

Site profile

OSHA 300A for this site, last 3 years

Use your 300A summary totals. G = deaths, H = days-away cases, I = job transfer/restriction cases, J = other recordable cases. Hours should include temp workers you supervise day to day (29 CFR 1904.31). Leave a year blank if you don't have it. Rates use the OSHA/BLS formula: cases × 200,000 ÷ hours.

YearTotal hours workedG deathsH days awayI restrictedJ other
2023
2024
2025

Optional: load a CSV with columns year,hours,G,H,I,J. It is read in your browser only. Remove employee names and any medical details first; the tool never needs them.

Fatalities and severe injuries

EMR (experience mod)

Optional but encouraged. Missing EMR is left out of the score, not counted against you.

OSHA citations, last 3 years

Look yourself up on the OSHA Establishment Search and enter counts here. Contested or deleted citations are shown but not deducted. Enter 0 if none.

TypeCount
Serious
Willful
Repeat
Other-than-serious
Failure to abate
Still open / not yet abated (any type)
Contested or deleted (not deducted)

Leading indicators (optional)

If you don't track any of these, this part scores 0. Not tracking them is the finding.

Written programs

The Core Nine programs count double. Mark "Not applicable" only if the hazard is truly not at this site (no forklifts, no respirators, no confined spaces, no noise above 85 dBA, and so on).

ProgramStatus
Lockout/tagout, machine-specific procedures (1910.147) Core Nine
Machine guarding (1910.212, .217, .219) Core Nine
Forklifts / powered industrial trucks (1910.178) Core Nine
Hazard Communication, updated for 2024 (1910.1200) Core Nine
Respiratory protection (1910.134) Core Nine
Hearing conservation (1910.95) Core Nine
Permit-required confined spaces (1910.146) Core Nine
Electrical safety program / NFPA 70E (1910 Subpart S) Core Nine
Ergonomics / material handling (General Duty Clause) Core Nine
Emergency action / fire prevention (1910.38/.39)
PPE hazard assessment (1910.132)
Walking-working surfaces / fall protection (1910 Subpart D)
Hot work (1910.252)
Cranes, hoists, slings (1910.179, .184)
First aid / bloodborne pathogens (1910.151, .1030)

Training

Contractors and temp workers

Leadership and resources (optional)

Culture questions

35 statements and 7 evidence questions across 7 areas. Answer for what actually happens on your floor, on every shift, not what the manual says.

0 Doesn't happen / don't know · 1 Happens after something goes wrong · 2 Written down, depends on the person · 3 Done consistently, checked by supervisors · 4 Operators drive it; we measure and improve it

Evidence caps each area: None → max 50, Verbal only → max 70, Document exists → max 90, Document + recent record → no cap. Claims need proof.

D1 · Leadership & accountability

1. Plant leaders walk the floor on every shift, nights included, specifically to talk safety at least weekly.

2. Safety is the first item in the daily production meeting, and actions from it get closed.

3. Scenario: a line is behind on a customer order and a guard is off for a "quick" adjustment. Production waits until the guard is back or the machine is locked out.

4. Supervisors' reviews weigh how they manage hazards, not just injury counts or output.

5. Money gets approved for guarding or ergonomic fixes without a fight.

Evidence: what could you show me? (Last 3 floor-walk notes, or a sample supervisor review.)

D2 · Change & task planning

1. New or moved equipment gets a hazard review (management of change) before it runs.

2. Non-routine jobs (jams, changeovers, cleaning, hot work) are planned before they start.

3. Scenario: maintenance gets a call at 2 a.m. to clear a jam on a running conveyor. The job is planned and locked out, even with no supervisor around.

4. Operators help write the job instructions for their own machines.

5. Hot work and other high-risk tasks need a permit signed off before work starts.

Evidence: what could you show me? (A recent management-of-change record or hot-work permit.)

D3 · Hazardous energy & machines Core hazard ×1.5

1. Every machine that gets serviced has its own written lockout procedure.

2. Lockout periodic inspections happen every year, and they find real things.

3. Guards are checked, and a missing or bypassed guard stops the machine.

4. Scenario: an operator reaches past a light curtain to clear a part "the way we always do." A supervisor stops it and the fix is to the machine or method, not just a warning.

5. Minor-servicing exceptions are written down and meet the rule; they are not used as a shortcut.

Evidence: what could you show me? (2 machine-specific lockout procedures and the last periodic inspection.)

D4 · Forklifts, chemicals & health exposures Core hazard ×1.5

1. Forklift operators are evaluated on the truck before they drive alone, and pre-shift checks are really done.

2. Pedestrians and forklifts are separated by layout and barriers, not just paint.

3. Workers can find the SDS and tell you the main hazard of the chemicals they use.

4. Scenario: a tank needs cleaning by confined space entry and the attendant gets called away. Entry stops until an attendant is back.

5. Noise and air are measured, and the results changed something (controls, not just earplugs).

Evidence: what could you show me? (A forklift operator evaluation and the latest noise or air-monitoring result.)

D5 · Reporting, learning & near misses

1. Operators report near misses and early aches or pain without fear of blame.

2. Every recordable gets a root-cause review that goes past "operator error."

3. Fixes favor engineering (guards, layout, tooling) over retraining and PPE.

4. Scenario: a lead hides a small hand cut to protect the department's safety bonus. We would find out, and we'd fix the reason it was hidden.

5. Lessons reach every shift within a week.

Evidence: what could you show me? (The last near-miss report and its closed corrective action.)

D6 · Competence & training

1. Training is checked by watching people do the task, not just by sign-in sheets.

2. Only named, trained authorized employees do lockout, and only qualified persons do electrical work.

3. New and temp workers are identified (sticker or buddy) and kept off high-hazard tasks until signed off.

4. Supervisors are trained to coach safety conversations, not just enforce rules.

5. Cross-trained operators are signed off on each machine before they run it alone.

Evidence: what could you show me? (A skills sign-off matrix or authorized / qualified-person roster.)

D7 · Contractors, temps & engagement

1. Outside contractors are prequalified on safety and coordinate lockout and hot work with us.

2. Temp and agency workers get the same orientation and hazard training as our own employees.

3. Operators have real input into how hazards on their machines are controlled.

4. Scenario: an operator stops a line because a guard is loose and production loses an hour. The operator gets thanked, not questioned.

5. Workers can stop work, and it has actually happened this year.

Evidence: what could you show me? (A contractor prequalification form or a stop-work record.)

EHS Concepts · Manufacturing Safety Diagnostic

Want Ryan to walk through your score? Book a $225 Working Session

Not a legal or compliance audit. Self-reported planning tool. Not an OSHA inspection, certification or legal advice. BLS rates are survey estimates and are known to undercount. Benchmarks: TRC (total recordable cases) and DART rates per 100 full-time workers (200,000-hour base) from the U.S. Bureau of Labor Statistics, Survey of Occupational Injuries and Illnesses 2024, Table 1. Your inputs come from your OSHA Form 300A.

Book a $225 Working Session

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Email me my summary

Coming soon. When this is switched on, only your first name, email, company-size range, maturity level and weakest area would go to our email list (Kit). Never your records, citations, injury details or company name.

How the score works (our method, published in full)

Overall = 50% records + 50% culture, then red-flag caps, then a records-vs-culture gap check.

Records (0–100): TRIR vs BLS benchmark 20 · DART vs benchmark 15 · EMR 10 · Citations 15 · Written programs 15 · Training 10 · Leading indicators 10 · Contractor and temp management 5. Rate curve: your rate ÷ benchmark ≤ 0.5 → 100, 1.0 → 60, ≥ 2.0 → 0. EMR: ≤ 0.80 → 100, 1.00 → 60, ≥ 1.25 → 0. Citations start at 100: −15 serious, −30 willful or repeat, −10 other, −20 failure to abate. Missing optional items are left out and the weights re-balance. Under 200,000 hours a year, rates are pooled across the 3 years.

Culture (0–100): area score = average answer × 25, capped by evidence. Hazardous energy & machines and forklifts/chemicals/health exposures count 1.5×.

Levels: 1 Reactive 0–39 · 2 Compliant-on-paper 40–59 · 3 Managed 60–74 · 4 Proactive 75–89 · 5 Operator-owned 90–100.

Red flags: a fatality, an amputation, or any willful or repeat citation caps you at Level 2. TRIR or DART at 2× benchmark or more caps you at Level 3. A missing lockout or guarding program (or no machine-specific lockout procedures) caps the hazardous-energy area at 50; a missing forklift, HazCom, respiratory, hearing or confined-space program caps the exposures area at 50. Open citations, confined spaces with no permit system, forklift drivers never evaluated, hearing-loss cases with no hearing program, no electrical qualified-person list, combustible dust with no hazard analysis, and EMR ≥ 1.25 are always flagged.