What If OSHA Walked In Tomorrow? How a Mock OSHA Inspection Can Help You Prepare
A Minute-by-Minute Look at What Inspectors Check First
OSHA inspections are rarely announced. One day you are focused on production, and the next there is an inspector at your door with credentials and questions. The companies that handle these visits best are the ones that have already practiced what to do.
In this article, we’ll walk you through what happens during the first hour of an OSHA inspection and how a Mock OSHA Inspection can help you prepare. You can also grab our free Mock OSHA Inspection Preparation Checklist here to follow along.
Before the Clock Starts: Why OSHA Arrives
According to the Occupational Safety and Health Administration (OSHA), inspections can be triggered by several events:
Employee complaints or referrals about unsafe conditions
Targeted programs focusing on high-hazard industries such as construction or manufacturing
Follow-up inspections from prior citations
Accidents or serious injuries that must be reported
Knowing these triggers helps you stay proactive. Having a plan before an inspector arrives can make the difference between a smooth inspection and a stressful one.
Learn more about how PCS Safety helps businesses stay inspection-ready at https://www.pcs-safety.com/.
Minute 0-5: Arrival and Opening Conference
The first few minutes set the tone. OSHA inspectors will:
Present credentials
Explain the reason for the visit
Outline the inspection scope
What you should do:
Verify credentials and record inspector details
Notify your safety lead or EHS manager
Identify PPE requirements for visitors
Escort the inspector safely into the facility
Pro tip: A calm, organized welcome signals that your company takes safety seriously.
Minute 5-10: First Impressions Count
Before reviewing any documents, inspectors take in their surroundings. They are looking for immediate hazards and signs of strong or weak safety culture.
Typical quick checks include:
Housekeeping and walking surfaces
Exit routes that are clear and properly marked
PPE being worn by employees
Machine guarding in place
Safety postings visible and up to date
Access to Safety Data Sheets (SDS)
If you spot something out of place, fix it now. These are easy citations to avoid.
Minute 10-20: The Records Review
This is where paperwork meets practice. Inspectors will ask to see:
Written programs such as Hazard Communication, Lockout/Tagout, Respiratory Protection, and PPE
Training records for employees and equipment operators
Injury and illness logs (OSHA 300 and 300A forms)
SDS and chemical labeling
Keep your records current, accessible, and consistent with actual work practices. A clean, well-organized safety binder creates immediate trust.
For a full list of required records, see OSHA’s Recordkeeping and Reporting page.
Minute 20-40: The Walkthrough
During the walkthrough, inspectors look for evidence of hazards and compliance issues. They will observe how employees work, how tools and equipment are used, and whether safeguards are in place.
Common focus areas include:
Energy control and machine guarding
Electrical panels and labeling
Forklift operation and charging stations
Egress routes and emergency exits
Ladders and scaffolding
Housekeeping, spill control, and ventilation
What inspectors often say: “Show me, not tell me.” Demonstrate safety practices in action instead of describing them.
Minute 40-50: Employee Interviews
Inspectors may select employees at random to ask simple but revealing questions:
How do you report a hazard?
Where are the SDS located?
What PPE do you need for your job?
When was your last safety training?
The goal is not to catch anyone off guard but to verify that safety communication is effective. Brief toolbox talks and consistent reminders help employees feel confident in their answers.
Minute 50-60: The Closing Conversation
After the walkthrough, inspectors often discuss next steps. If serious hazards are observed, the inspection may expand or include additional areas. If everything looks good, the visit may move toward a closing conference.
At this stage:
Take your own notes and photos
Record any potential violations or items to review later
Start outlining who will take corrective action and by when
A strong internal follow-up plan can turn inspection feedback into meaningful improvement.
The Safe Check Challenge
Not sure how your workplace would perform? Try the Safe Check Challenge, a quick self-audit you can run in less than 20 minutes.
Pick one production line.
Verify that Lockout/Tagout devices match written procedures.
Confirm that all machine guards are installed.
Ask two employees to show where safety information and SDS are located.
You’ll learn more in 20 minutes than most facilities do in a week of meetings.
➡️ Download the checklist to record your results.
Practice with a Mock OSHA Inspection
A Mock OSHA Inspection is the smartest way to prepare. It mirrors the real process so you can identify and correct issues before OSHA does.
When you schedule a mock inspection with PCS Safety, our consultants will:
Conduct an opening review and discuss scope
Review your written programs and training records
Walk through your facility and equipment
Interview employees for readiness and awareness
Provide a detailed findings report with risk-ranked corrective actions
This proactive approach helps you avoid penalties, reduce downtime, and build a stronger safety culture.
📋 Schedule a discovery call to discuss a mock inspection for your facility.
If You Already Have a Citation
Receiving a citation is stressful, but it’s not the end of the story. You have 15 working days to act, and what you do in that window can drastically affect the outcome.
PCS Safety’s mitigation team can:
Guide you through the informal conference process
Help you develop proof of abatement with photos, invoices, and updated training
Reduce penalties through corrective action documentation
Support your team in preventing repeat violations
Learn more about mitigation services and how PCS Safety can help by visiting https://www.pcs-safety.com/contact/.
Turn Every Inspection Into Progress
An OSHA inspection doesn’t have to be a disruption. When you practice, document, and correct early, you turn compliance into confidence.
Start with our free Mock OSHA Inspection Preparation Checklist — your step-by-step tool for self-assessment, improvement, and readiness.
➡️ Download the checklist here
➡️ Contact PCS Safety for professional guidance
About PCS Safety
At PCS Safety, we make workplace safety simple, effective, and sustainable. Our experienced team helps California manufacturers and construction companies stay compliant with OSHA, reduce risk, and protect their people through training, written programs, audits, and on-site support.
Disclaimer: The information provided in this article is for general informational purposes only and is not intended to serve as legal or professional safety advice. For assistance with OSHA compliance or workplace safety programs, please contact PCS Safety.
