Know about the near miss before it becomes the injury
Near misses, injuries and fixes in one record, tied to work orders.
Who this is for
Operators and supervisors report; the EHS lead investigates. You own the site's results and often certify the OSHA 300A.
You answer to
SAMPLE RECORD · SYNTHETIC DATA
What makes this job hard today.
A report competes with the schedule
A report that takes a supervisor off the floor loses to the production plan. So near misses stay unreported until one becomes an injury.
Four owners, four records
Safety has the injury, maintenance the work order, quality the nonconformance and HR the claim. Each tells a different story.
Fixes wait for downtime
The right fix needs the line down, and downtime needs approval. Weeks pass. Nobody checks if the fix worked.
You sign for the plant
You may be the top official on site, who can certify the 300A. Where process safety management applies, an investigation must start within 48 hours.
The work, in your terms.
- Near misses: pinch points, forklift and pedestrian conflicts, dropped loads
- Injuries that need a recordable decision
- Lockout/tagout events and bypassed interlocks
- Machine guarding incidents and unexpected startups
- Chemical releases and near-miss releases
- Fires and smoke events
- Contractor injuries on site
- Forklift and powered industrial truck incidents
- Equipment failures that stopped the line
- Slips, trips and falls
- Workplace violence and threats
- Corrective actions waiting on downtime or a work order
What you answer to.
- OSHA recordkeeping, 29 CFR 1904
- Keep a separate 300 Log for each establishment and enter recordable cases within seven calendar days. A company executive certifies the 300A. Post it February 1 through April 30.
- Severe injury reporting, 29 CFR 1904.39
- Report a fatality within 8 hours and an inpatient hospitalization, amputation or loss of an eye within 24 hours.
- Lockout/tagout, 29 CFR 1910.147
- Inspect each energy control procedure at least annually to make sure the procedure and the standard are being followed.
- Process safety management, 29 CFR 1910.119(m)
- Where covered, investigate any incident that did or could have caused a catastrophic release of a highly hazardous chemical. Start within 48 hours, document findings and keep reports five years.
- NIOSH hierarchy of controls
- Elimination, substitution, engineering controls, administrative controls, then personal protective equipment, from most to least effective.
- BLS incidence rates
- Rate equals cases times 200,000 divided by employee hours worked. The DART rate counts days away, restricted or transferred cases.
A conveyor near miss on third shift
The line restarts while an operator clears a jam, nobody is hurt, and the report still matters.
01Report
Supervisor scans QR and texts Lauren
The operator's hand is clear when the conveyor restarts.
The supervisor scans the QR code on the conveyor and texts Lauren.
Lauren asks about the lockout step
Lauren asks for the equipment ID, task, lockout step, who restarted the line and whether a guard was in place.
The draft is marked 'Lauren · draft'.
Signed report routes to EHS lead
The supervisor edits and signs. Routing sends it to the EHS lead and plant manager because it is a near miss involving energy control.
02Investigate
EHS lead starts the investigation
At shift handoff the plant manager opens the report.
The EHS lead starts an investigation with the team lead and a maintenance technician.
Investigation finds no lockout point
The cluster view shows a similar near miss on the sister line five weeks earlier.
The jam-clearing procedure had no lockout point on this line.
03Correct
Engineering and procedure actions created
An engineering action adds a lockout point and interlocked door on both lines.
An administrative action revises the procedure. Maintenance adds the work order number to each action.
Effectiveness check closes both actions
The check finds no jam-clearing events with energy exposure on either line.
The EHS lead verifies the evidence and the actions close.
04Prove
Annual inspection uses the record
The periodic inspection under 29 CFR 1910.147(c)(6) uses the record: the near miss, the finding, the fix and the check.
Illustrative scenario. Details are invented to show how the workflow runs.
See this on your team.
Thirty minutes, built around your incidents, your regulator and the proof you have to produce.
Set up for your kind of site.
Forms, routing, exports and roles are configured per site. We load them for you on paid plans.
Forms
- Near miss and hazard report, with QR quick report on equipment
- Injury and illness report with recordability questions
- Equipment and process incident report
- Contractor incident form
- Corrective action plan with work order and effectiveness check
Routing
- Alerts to EHS and plant manager by severity and equipment
- Instant alert for hospitalization, amputation, eye loss or fatality
- Maintenance notice when an action needs a work order
- Overdue-action reminders to the owner, then the plant manager
Exports
- OSHA 300, 300A and 301 (rolling out)
- Analytics by equipment, shift, location and cause
- Investigation report: team, contributing factors, recommendations
- Read API and signed webhooks
Roles
- Plant manager: reads across the site, certifies the record
- EHS lead: classifies, investigates and signs
- Supervisors: first-line review
- Maintenance, quality and operations: close actions with evidence
Outcomes you can plan for.
Near misses that get reported
A text or QR code takes less time than a form, so reports compete less with the schedule. See near-miss reporting.
One record, not four
The report, investigation, actions and work order reference sit together, so the shift meeting starts with the same facts.
Fixes that prove themselves
An action closes only after evidence and an effectiveness check are verified, so a failed fix stays open. See close corrective actions.
Patterns across lines and sites
Clusters by equipment, shift, location and cause show where the same event happens twice, even across plants.
The rules behind this pack.
Plant managers: frequently asked
Something we missed? Ask us, and a person answers.
Is the plant pack available today?
Industry packs beyond healthcare are rolling out, and healthcare packs are available now. OSHA 300, 300A and 301 exports are also rolling out. Contact us to see what is ready for your site.
Does IncidentKit replace our CMMS?
No. It runs alongside your CMMS, EHR and HRIS. You can record a work order number on an action today. Deeper CMMS integrations are rolling out; the platform offers signed webhooks and a read API.
Does it support PSM incident investigations?
Yes. It gives an investigation the structure PSM asks for: a team, description, contributing factors, recommendations, documented resolutions and an audit trail. Whether process safety management covers your process depends on the chemicals and quantities, so check 29 CFR 1910.119. See process safety incident investigation.
Who certifies the OSHA 300A at a plant?
A company executive: an officer of the corporation, the highest-ranking company official at the establishment, or that official's immediate supervisor. At many plants that is the plant manager. Post the summary from February 1 through April 30. See OSHA 300A.
How do contractor injuries work?
Whoever supervises the worker day to day records the injury: the contractor if it does, you if you do (29 CFR 1904.31). The same test applies to temporary and leased workers. Contractor and visitor incidents have their own form and routing. See contractor and visitor incidents.
See it on your team.
Tell us about your sites and we will build the demo on your kind of facility. Or start free and report something real today.