10 Industrial Safety Rules and Essential Tips To Follow Them Effectively

At SHIIFT, we specialize in developing interactive training solutions that help industries improve workplace safety and reduce risks. From Virtual Reality (VR) simulations to eLearning, we’ve seen firsthand how proper training can prevent accidents and save lives.

A key part of environmental health and safety in industrial organizations is Stop Work Authority (SWA), ensuring every worker has the right to pause any task that appears unsafe. No job is worth risking an injury, and fostering a culture where employees feel empowered to speak up can prevent serious incidents.

Industrial workplaces come with inherent hazards, from heavy machinery to hazardous materials. Following strict safety rules is essential to protecting workers and ensuring smooth operations, as well as avoiding heavy fines from OSHA if your an employer. Whether you’re in manufacturing, construction, or warehousing, these 10 general industry safety rules should always be followed.

1. Wear Proper Personal Protective Equipment (PPE)

Incorrect use of or complete disregard of PPE is easily one of the leading causes of workplace injuries and fatalities, it comes as no surprise that Fall Protection, Respiratory Protection, Eye and Face Protection, all PPE related safety standards have been cited by OSHA as 3 of the (preliminary) top ten list of most frequently violated standards of the fiscal year 2024.

Personal Protective Equipment (PPE) is the first line of defense against workplace hazards, so always make sure to use the correct PPE for the job, including safety helmets, gloves, eye protection, hearing protection, respiratory protection, steel-toe boots etc (depending on your specific work environment). The right gear and making sure you are fully trained in correctly wearing/using the gear can prevent serious injuries.

How to Follow This Safety Rule Effectively:

• Know which PPE is required for each task.
  Different tasks require different protective gear. Make sure to learn which PPE is required for each different tasks by reading safety manuals, using training programs, or asking supervisors for each specific procedure.
• Ensure PPE fits properly and is comfortable to wear.
  PPE that doesn’t fit can be ineffective and even dangerous. Tight gloves can reduce grip, loose clothing can get caught in machinery, and oversized eyewear can leave gaps for debris. Always select the correct size and adjust straps or fastenings as needed.
• Inspect PPE before each use.
  Check for cracks, wear and tear, or contamination before putting on PPE. Damaged gear won’t provide proper protection and should be replaced immediately.

2. Follow Lockout/Tagout (LOTO) Procedures

Lockout Tagout (LOTO) is a safety procedure used to ensure that machines are properly shut down and unable to start before maintenance or repair work begins. Before servicing or maintaining machinery, technicians always need to ensure proper lockout/tagout procedures are in place to prevent accidental machine startups and protects workers from hazardous energy. 

This is another of the most often violated safety standards in industrial workplaces, with it coming in 5th most cited violated safety rule and being cited in the top 10 for at least the last 30 years. 

How to Follow This Safety Rule Effectively:

• Incorporate the tryout step to enhance safety, from lockout/tagout to lockout/tagout/tryout (LOTOTO).
  This might sound silly, but you should never assume that a machine is off just because you turned it off, even if it isn’t moving or making noise. Test controls, check power indicators, press the start button and confirm with a multimeter if necessary to ensure no residual energy remains.
• Be aware of stored and residual energy.
  Some machines retain energy even after being powered down, such as hydraulic pressure, compressed air, or electrical capacitance. Follow proper release procedures to discharge stored energy before starting maintenance.
• Train all affected employees on LOTO procedures.
  Even workers who don’t directly perform lockout/tagout should understand the process and why it’s critical. Accidents often happen when an uninformed worker assumes a machine is safe to operate.

We have a highly in-depth text-based guide on our website as well as LOTOTO VR Simulation for more hands-on training which available for purchase with bespoke customizations if you contact hello@shiifttraining.com

3. Use Equipment and Machinery Correctly

Industrial machinery is designed with specific safety features and operational procedures to prevent accidents. Even experienced workers should never assume they can bypass safeguards or take shortcuts when using equipment. 

Never bypass safety guards or use machines beyond their intended purpose. Always follow manufacturer guidelines and receive proper training before operating equipment.

How to Follow This Safety Rule Effectively:

• Read and follow manufacturer guidelines.
  Every machine has an operator’s manual that explains proper usage, safety precautions, and maintenance requirements. Make sure you understand these guidelines before operating any equipment.
• Attend proper training before using new machinery.
  Even if a machine seems similar to one you’ve used before, differences in controls, power sources, or safety mechanisms can make a big difference. Hands-on training and refresher courses help prevent errors.
• Never remove or disable safety guards.
  Guards, sensors, and emergency stop mechanisms are designed to prevent direct contact with hazardous parts. Removing or bypassing them might make work seem faster or easier, but it significantly increases the risk of injury.
• Inspect equipment before each use.
  Before starting a machine, check for damaged cables, loose bolts, leaks, or worn-out parts. Report and do not use defective equipment until it has been properly repaired.
• Use the correct tools and attachments.
  Avoid using the wrong tools for the job. Machines are designed to function safely with specific accessories, and using unapproved tools can lead to malfunctions.
• Maintain focus while operating machinery.
  Distractions, fatigue, and complacency can lead to critical mistakes. Avoid phone use, unnecessary conversations, or rushing through tasks when working with heavy equipment.

4. Keep Work Areas Clean and Organized

This is one of the more forgotten rules of safety in industrial work, but keeping clean isn’t just about appearances, it actually has a massive impact on safety and can be the difference maker in saving lives, especially in working at height situations or areas with sharp objects around.

Cluttered work areas increase the risk of trips, slips, and falls. Keep floors dry, aisles clear, and tools properly stored to maintain a safe environment.

How to Follow This Safety Rule Effectively:

• Regularly remove debris and spills to prevent trips and falls
  Use spill kits, absorbents and proper waste disposal to take care of slipping hazards. Don’t wait for scheduled cleanups, don’t rely on people noticing the ‘caution wet floor’ sign, address slip hazards ASAP.
• Store tools and materials in designated locations to reduce clutter
  Keep aisles and work surfaces clear easily, by returning tools to their proper storage place after you’re done with them.
• Keep emergency exits and pathways clear at all times
  Blocked emergency exits or pathways are an easy way to obstruct escape routes and delay evacuations.

5. Report Unsafe Conditions Immediately

If you notice damaged equipment, exposed wiring, spills, or any potential hazards, report them to a supervisor immediately. Early reporting helps prevent accidents. Don’t be afraid to use your stop-work authority if you feel someone else is being unsafe.

No matter how small an unsafe condition seems, whether it’s an unmarked spill or someone missing PPE, if you don’t do something about it something can go wrong

How to Follow This Safety Rule Effectively:

• Familiarize yourself with reporting procedures and who to contact.
  Every workplace should have a clear system for reporting hazards, whether it’s through supervisors, safety officers, or digital reporting systems.
• Never assume someone else will report the hazard
  Report hazards immediately without delay, take initiative and don’t rely on others  reporting the hazard before you do.

6. Follow Fire Safety Protocols

Fires can spread rapidly in industrial settings, especially when flammable materials, electrical equipment, and high heat sources are present. Knowing how to prevent fires and respond correctly can save many lives in your workplace.

Know where fire extinguishers, emergency exits, and evacuation routes are located. Never block fire exits, and always store flammable materials properly.

How to Follow This Safety Rule Effectively:

• Keep flammable materials stored away from ignition sources.
  Properly store and label combustible liquids, gases, and chemicals to reduce fire risk.
• Participate in fire drills and understand emergency evacuation plans.
  Treat every drill seriously, knowing exit routes and meeting points ensures a faster, safer evacuation during real emergencies.

7. Lift Heavy Objects Correctly

Improper lifting techniques cause musculoskeletal injuries, which are aa very common workplace injury. Proper lifting reduces strain on your body and even prevents long-term health issues.

Use proper lifting techniques, Bend at the knees, keep your back straight, and lift with your legs. For heavy loads, use mechanical aids or ask for help to avoid injury, and always make sure to use the appropriate and certified lifting gear to help you.

How to Follow This Safety Rule Effectively:

• Assess the weight before lifting and use mechanical aids for heavy loads.
  If an object is too heavy or awkward to carry alone, use dollies, forklifts, or get team assistance.
• Keep your back straight and lift with your legs, not your back.
  Always let your legs do most of the work by keeping the load/object close to your body while lifting. Avoid rounding your spine to prevent strain.
  
• Avoid twisting while lifting; instead, move your feet to change direction.
  Rotating your torso while lifting increases the risk of back injuries. Pivot using your feet instead of twisting your spine.

Lifting techniques compared with improper lifting (left side) and proper lifting technique (right)

8. Stay Aware of Surroundings

A distracted worker is a dangerous worker. Many accidents happen because people aren’t paying attention to moving machinery, falling objects, or coworkers operating equipment.

On top of this, industrial settings tend to be noisy and busy. Stay alert, avoid distractions (such as using phones in high-risk areas), and be mindful of moving vehicles, forklifts, or overhead hazards.

How to Follow This Safety Rule Effectively:

• Avoid distractions such as phone use in high-risk areas.
  Focus fully on your task but don’t ignore your surroundings, especially when working near machinery, vehicles, or hazardous zones.
• Always make eye contact with forklift or vehicle operators before crossing their path.
  If an operator doesn’t see you, they won’t stop, so make sure to always confirm visual communication before walking in front of a moving vehicle.
• Be mindful of overhead hazards, moving machinery, and other workers.
  It’s nice to always feel safe and trust equipment and other workers, but something can always go wrong without expecting it, so stay alert to falling tools, suspended loads, and automated equipment that may operate unexpectedly.

9. Adhere to Chemical Safety Guidelines

If working with hazardous chemicals, always read safety data sheets (SDS), wear the necessary PPE, and ensure proper ventilation. Improper handling of chemicals can cause burns, repsiratory issues, and even explosions so follow these chemical workplace safety tips to make sure you and other don’t fall victim to a chemical hazard.Never mix unknown substances.

How to Follow This Safety Rule Effectively:

• Read and understand Safety Data Sheets (SDS) fully before handling chemicals related to your process
  SDS documents outline hazards, handling procedures, and emergency response actions. Never assume a chemical is safe without checking all the details for actually using it safely first.
• Wear appropriate PPE, including gloves and eye protection, when dealing with hazardous substances
  Chemical splashes can cause severe injuries, so always always wear chemical-resistant gloves, face shields, or respirators as needed according to the safety data sheet.
  
• Ensure proper ventilation and avoid mixing unknown chemicals
  Some chemicals release toxic fumes when mixed. Work in well-ventilated areas and only mix chemicals when explicitly instructed by someone who understands how to stay safe with the chemicals.

10. Attend Safety Training and Drills

Regular safety training ensures workers stay updated on protocols. Participate in fire drills, emergency response training, and equipment handling courses to stay prepared and up to date on new safety regulations, best practices or any information at all.

How to Follow This Safety Rule Effectively:

• Actively participate in training sessions
  Don’t just sit through your training and learn passively and uneffectively, engage with instructors, coworkers and learning materials as best you can, and ask questions if unsure to clarify all your uncertainties.
• Keep up-to-date with the latest safety procedures and protocols
  Safety standards evolve, with new equipment, chemicals or procedures sometimes needing updated knowledge.

Final Thoughts: The Most Important Industrial Safety Rule of All

Knowing these 10 safety rules is a great start, but the most important rule isn’t on the list. The real key to workplace safety is following the rules every single time. Of all risks in industrial settings, overconfidence is the one thing that causes more accidents than all the rules above can protect you from.

It’s easy to feel safe when you’ve done a task thousands of times. You might think, “I know what I’m doing,” or feel pressure to get the job done faster by skipping a step. But safety procedures exist because accidents happen when we least expect them. Many incidents occur not due to a lack of knowledge, but because someone cut corners, ignored a rule, or got too comfortable.

No deadline, routine task, or past experience is worth risking your safety. The best way to protect yourself and others is simple: stay vigilant, follow the rules, and never assume that just because nothing has gone wrong before, it won’t happen now.