Surviving My First OSHA Inspection: Lessons Learned

If you’ve never been through an OSHA inspection, you likely don’t know what to expect.

Today, I want to share the story of my first OSHA audit—what I was thinking, the experience itself, and the lessons learned along the way. My goal is to help you prepare your team so that you can avoid the pitfalls I encountered. Trust me, it will make your life a lot easier.

Before we jump in, if you don’t have an OSHA audit checklist, take a moment to download one for free from my website, Help with OSHA. This quick guide will walk you through everything you need to prepare your team for an unexpected OSHA visit. It’s worth your time!

The Backstory: How It All Started

Right out of college, I worked in fiberglass boat building—a job I loved. Through a series of unexpected events, I transitioned into safety training and consulting. After a few years in that field, I found myself at a food processing plant as a safety manager. Like many of you, I wore multiple hats:

• People Safety: Ensuring OSHA compliance.

• Food Safety: Protecting customers from unsafe products.

• Quality & Environmental Management: Overseeing additional operational priorities.

Despite these responsibilities, my focus was often on food safety and quality, as directed by my boss. Safety, while important, wasn’t always the top priority. That context sets the stage for what happened next.

The Day of the Inspection

It was a typical mid-week morning, and I had just come out of a meeting with a to-do list a mile long. That’s when I got the text: “OSHA is at the front door. We need you now.” My stomach dropped. I’d never dealt with an OSHA inspector before, and all I could think was how this was going to derail my already packed day.

The Opening Conference

When I reached the front office, the vibe was tense. The inspector had already rubbed our receptionist the wrong way by asking, “I want to speak to the person who makes the most money here.” This set a negative tone right off the bat. Nevertheless, I led the inspectors to the conference room, where they conducted their opening conference and explained the purpose of their visit—an employee complaint about machine guarding and lockout/tagout procedures.

The Walkaround

During the walkthrough, I stuck to showing them only what they needed to see. While I felt reasonably confident in our safety programs, it was clear that I hadn’t prepared the rest of the team for this scenario. Employees were visibly nervous, management was unsure how to act, and there was no clear game plan.

The inspectors noted a few issues, took pictures, and left us with a list of items to address. By the time they left, I was mentally and physically drained.

Lessons Learned

Looking back, that first OSHA inspection taught me three critical lessons:

1. Preparation is Everything

I learned the hard way that preparation is key. Having a clear, actionable plan in place can make all the difference. Here’s what you need:

• Roles & Responsibilities: Assign a point person for regulatory visits.

• Training: Ensure employees know how to interact with inspectors.

• Documentation: Keep all safety programs, training records, and inspection logs up-to-date.

2. Mindset Matters

The experience highlighted the importance of approaching an inspection with the right mindset. Everyone—from leadership to frontline workers—needs to view OSHA as a partner in safety, not an adversary. A cooperative attitude can significantly improve the outcome.

3. Be Proactive, Not Reactive

That inspection made me realize how much time I spent reacting instead of planning. A proactive safety program includes:

• Regular internal audits.

• Mock OSHA inspections.

• Continuous improvement initiatives.

The Outcome

While the inspectors found a few minor issues, we addressed them promptly and successfully negotiated reduced penalties at an informal conference. However, the process was far from smooth. My lack of preparation and my boss’s adversarial approach made it more stressful than it needed to be.

Final Thoughts

Surviving an OSHA inspection isn’t just about avoiding fines—it’s about creating a safer workplace for everyone. By learning from my experience and adopting a proactive approach, you can turn a potential crisis into an opportunity for improvement.

Don’t forget to download your free OSHA audit checklist from my website to get started. Preparation makes all the difference!