Personal Protective Equipment (PPE) Checklist

Walk every work center and document hazards by task per 29 CFR 1910.132(d) — impact, penetration, compression, chemical, heat, dust, optical radiation, noise. The certification must be signed, dated, and identify the workplace evaluated; a generic plant-wide assessment will not survive an OSHA citation.

Cross-reference each task hazard against the PPE selection matrix. Verify ANSI/ISEA ratings — Z87.1 for eye/face, Z89.1 for hard hats, Z41/F2413 for footwear, ANSI/ISEA 105 cut/abrasion levels for gloves. Substitutions like nitrile for chemical-resistant butyl are a common gap.

Each employee should have a signed acknowledgment of PPE received, training completed, and replacement schedule. New hires and transfers between work centers are the most common gaps.

New equipment, new chemicals on the SDS list, process changes, or ECNs since the last review can introduce hazards the current PPE program does not cover. Flag any change for re-assessment.

Safety glasses, goggles, and face shields must carry the ANSI Z87.1 stamp on the frame and lens. Welding shields require the appropriate shade number per AWS — shade 10 for stick electrode under 160A, higher for MIG and plasma.

Pull representative units from each cell — pitting, cracks, scratched lenses that obscure vision, missing side shields. Damaged eyewear is removed from service the same shift.

ANSI Z358.1 requires weekly activation and annual full inspection. Stations must reach injured workers within 10 seconds of travel and deliver tepid water for 15 minutes. Verify the weekly activation log is signed.

Reference ANSI/ISEA 105 cut, puncture, and abrasion ratings for mechanical hazards; SDS Section 8 for chemical permeation breakthrough times. Common gotcha: latex or nitrile against solvents — the wrong material gives false confidence.

Inspect 5-10 pairs from the highest-use cells. Look for thinning at fingertips, cuts in palm reinforcement, swelling or stiffness from chemical exposure. Record any glove returning a defect rate above 10% as an open finding.

Defect rate above 25% suggests wrong glove spec, supplier quality slip, or task hazard not captured in selection. Open a corrective action with effectiveness verification — track defect rate for two cycles after the change before closing.

OSHA 1910.134 requires a written program with a designated administrator, selection criteria, medical evaluation, fit testing, and cartridge change-out schedule. Voluntary-use N95s still require Appendix D notification.

Each user needs a current OSHA Respirator Medical Evaluation Questionnaire (Appendix C) reviewed by a PLHCP before any fit test. Fit-testing an unclearred user is one of the most cited 1910.134 violations.

Pull users without current Appendix C off any task requiring respirator use until the PLHCP review is complete. Schedule the medical evaluation through the contracted occupational health provider.

Use a recognized OSHA protocol — Bitrex, saccharin, or quantitative PortaCount. Re-test annually, after weight change, dental work, or facial scarring. Record make, model, and size for each user.

Per 1910.95, action level is 85 dBA TWA. Above that, hearing conservation program kicks in — annual audiogram, training, hearing protection offered. Posted noise maps should reflect the most recent dosimetry, not a 2018 baseline.

Apply the NIOSH derating: subtract 7 from labeled NRR, then divide by 2 for foam plugs (50% derating). A 33 NRR plug delivers about 13 dB real-world. Verify residual exposure is under 85 dBA after derating.

ANSI Z89.1 hard hats: replace shell every 5 years from manufacture date (stamped inside), suspension every 12 months, immediately after any impact. Stickers and paint can hide cracks and degrade the shell.

Pull the LMS roster (KPA Flex, Intelex, SafetyCulture, or paper) and confirm every active employee has current PPE training, hazard communication, and equipment-specific certifications. Flag transfers and contractors most often missed.

Pull anyone without current training off restricted tasks until completion. Training must include why each PPE item is needed, when, how to don/doff, limitations, and care — generic videos do not satisfy 1910.132(f).

Layered process audit by EHS plus the production supervisor — observe actual PPE use, not just availability. Note any safety glasses on top of the head, gloves stuffed in pockets, or chin straps unbuckled. Findings drive the corrective-action backlog.