How Manufacturing Plant Accidents Happen — and What the Regulations Require
Plant injuries tend to cluster around a few kinds of hazards: process equipment that starts or releases energy while someone is servicing it, elevated platforms and walkways with open sides, chemicals that are handled or stored nearby, and the gaps that open when crews from different companies work on the same machine. Federal standards speak to each of these.
Chemicals on site. The purpose of the hazard communication standard, 29 C.F.R. § 1910.1200(a), is to ensure that the hazards of all chemicals produced or imported are classified, and that information about those classified hazards is transmitted to employers and employees, through programs that include container labeling and other forms of warning, safety data sheets and employee training. According to OSHA's hazard communication page, chemical manufacturers and importers are required to evaluate the hazards of the chemicals they produce or import and prepare labels and safety data sheets for their downstream customers, and all employers with hazardous chemicals in their workplaces must have labels and safety data sheets for exposed workers and train them to handle the chemicals appropriately. On a shared plant, hazard information is supposed to travel from the chemical's maker, to the companies using it, to the workers near it, so the questions of who supplied the chemical and who was responsible for its labels and training often come up.
Servicing and lockout. The lockout/tagout standard covers servicing and maintenance of machines where unexpected start-up or release of stored energy could injure employees. Under 29 C.F.R. § 1910.147(f)(2), whenever outside servicing personnel do work covered by the standard, the on-site employer and the outside employer must inform each other of their lockout or tagout procedures, and the on-site employer must ensure its own employees understand and comply with the restrictions and prohibitions of the outside employer's energy control program. This rule is built for exactly the moment when two companies' crews meet at one machine, which makes whose crew was servicing the equipment, and whose lockout procedure was in use, central facts.
Platforms and edges. Under 29 C.F.R. § 1910.28(b)(1), except as provided elsewhere in that section, the employer must ensure that each employee on a walking-working surface with an unprotected side or edge 4 feet or more above a lower level is protected from falling by one or more of guardrail systems, safety net systems, or personal fall protection systems such as personal fall arrest, travel restraint or positioning systems. On a plant with mezzanines and catwalks, the height of the edge and the protection in place both matter, as does who installed, removed or maintained the guardrail or fall equipment at that spot.
A standard does not by itself show that anyone was at fault. Whether its requirements applied, whether they were met, and whether a failure caused the injury all depend on the facts.