Explore real-world workplace safety lessons to help reduce risks, protect employees and avoid costly mistakes.
Quick Takeaways
- Understanding why fall protection violations top OSHA’s list can help you identify risks before they lead to costly fines or compliance issues for your clients.
- Learn how oversights, like a bakery’s failure to implement lockout/tagout procedures, can serve as cautionary tales to improve safety strategies.
- See how innovative tools, like wearable safety technology, are reshaping workplace risk management and offering opportunities to reduce injuries and costs.
Experience is a valuable teacher, but when it comes to safety, firsthand experience is not always desirable. For agents, helping clients learn from the mistakes of others can be an impactful way to prevent injuries and avoid costly penalties before they occur.
Both the successes and failures of other organizations can provide crucial workplace safety lessons and insights into best practices. In that spirit, here are five real-world cases from 2024 that highlight critical safety lessons.
1. Repeated safety violations lead to costly penalties
One of the most dramatic safety violations of the year came from a Zion, Illinois-based contractor called Corner Construction. In December 2024, the Occupational Safety and Health Administration (OSHA) fined the company $266,175 for allowing crews to work on a roof without fall protection. More concerningly, it was the second such incident in six months and the fifth in two years for the contractor.
While Corner Construction’s workers didn’t suffer any injuries in this case, it highlights the need for stronger enforcement of safety standards. Had the company required employees to follow OSHA protocols, they could have avoided hundreds of thousands of dollars in penalties.
Fall protection was the most-cited OSHA violation for the 14th consecutive year in 2024. This highlights the opportunity to guide clients toward adopting comprehensive risk management strategies and insurance coverage that accounts for these risks, both to help businesses avoid injuries and save on costly injuries.
Related: Nighttime construction safety: Tips to keep workers safe on the job
2. The cost of ignoring lockout/tagout procedures
Major safety cases are not unique to the U.S. Another noteworthy example from 2024 comes from the U.K., where a bread supplier called Jacksons Bakery faced fines of over £360,000 — roughly $447,000 — when an employee lost a finger.
The staff member was attempting to clear a blockage from a machine when it caught and amputated part of his hand. Like in the United States, U.K. law requires equipment to be locked and tagged out during dangerous maintenance, which the bakery failed to do in this instance. The engineer who suffered the injury also did not know the machine was running while working on it.
This case is a jarring example of why businesses must have a strict lockout/tagout procedure. Such measures not only protect workers but can also reduce exposure to liability, which is an area where having tailored insurance solutions can make all the difference.
3. Lessons on ergonomic safety from a high-profile case
E-commerce giant Amazon also made headlines in 2024 for its safety violations. The company reached a settlement with OSHA in December 2024, agreeing to pay a $145,000 penalty and adopt new workplace safety measures across all its facilities.
The settlement was over reported issues with workers’ ergonomic safety. Musculoskeletal injuries can start small and build slowly, making them easy to overlook, but they have dramatic consequences. Ergonomic issues from snow shovels alone send thousands of people to the emergency room annually.
This largest-of-its-kind deal with OSHA emphasizes the need for ergonomic protection, especially in warehouses. Businesses implementing ergonomic improvements — such automating repetitive tasks, placing objects at waist height and providing employees with lifting equipment — not only reduce injury rates but also demonstrate a proactive commitment to employee safety. This approach can also lower risk-related insurance premiums over time!
Related: A practical guide to reducing on-the-job injuries
4. An award-winning approach to workplace safety
Not all workplace safety stories from the last year were negative. Some businesses have made significant positive strides in their safety management, and they deserve just as much attention.
Enova Premier — an auto parts manufacturer in Michigan — received a Gold award from the state’s Consultation Education and Training Division. The prize recognizes the manufacturer’s injury rates remaining below average for two consecutive years. Beyond protecting workers, Enova Premier’s safety measures have led to increased productivity and reduced costs.
It’s important to realize that Enova Premier only achieved this status after performing an OSHA consultation, which revealed several unaddressed hazards. By addressing these risks within 30 days, the company improved employee working conditions and significantly reduced liability exposures — ultimately benefiting both their workforce and their bottom line. Enova Premier’s success also highlights workplace safety lessons that can inspire other organizations to take proactive steps.
Related: How to help your clients achieve lower workers’ comp rates
5. Innovative technology reduces workplace injuries
Another positive example comes from Sun City Palm Desert, a country club and adult community in Palm Desert, California. The facility saw an 80% reduction in some workplace injuries after implementing wearables to track ergonomic risks.
Many of Sun City’s employees go through repetitive motions and must lift objects throughout their workday. Consequently, musculoskeletal disorders are a prominent concern, but the unique work environment makes conventional protections difficult to install. Instead, the company found success by giving workers wearable devices that vibrate when they detect unsafe movement.
A simple reminder is sometimes all it takes to prevent hazardous behavior, and wearables provide the real-time responsiveness necessary. Other businesses can learn from this example and consider how technology can support their own safety goals.
Learn from these real-world cases
The mistakes and successes of others offer valuable workplace safety lessons for your clients. These examples not only highlight the importance of safety protocols but also underscore the role of thoughtful risk management and tailored insurance solutions in creating long-term stability. And for businesses looking to take proactive steps, connecting with experienced partners can make all the difference.
Looking for ways to help your clients navigate workplace risks? Arrowhead provides insurance solutions and resources to support businesses in staying compliant and safe. Explore our programs.