Chemical Safety in Manufacturing: SDS Best Practices for Plant Managers

The Manufacturing Safety Challenge

Manufacturing facilities often work with hundreds or even thousands of different chemicals — from raw materials and process chemicals to maintenance products and waste streams. Managing SDSs at this scale requires a systematic approach that goes far beyond a filing cabinet.

OSHA's Hazard Communication Standard applies to every manufacturer that uses, stores, or produces hazardous chemicals. With the volume and variety of chemicals in a typical plant, staying compliant requires purpose-built systems and processes.

Categories of Manufacturing Chemicals

Production Chemicals

• Raw materials and feedstocks
• Catalysts and reagents
• Solvents (acetone, toluene, MEK, xylene)
• Acids and bases (sulfuric acid, hydrochloric acid, sodium hydroxide)
• Resins, polymers, and adhesives

Metalworking

• Cutting fluids and coolants
• Lubricants and hydraulic fluids
• Rust preventatives
• Welding gases and fluxes
• Plating and finishing chemicals

Maintenance

• Degreasers and parts washers
• Paints, primers, and coatings
• Compressed gases
• Sealants and caulks

Facility Operations

• Cleaning chemicals
• Water treatment chemicals
• HVAC refrigerants
• Laboratory reagents (for QC)

Scaling SDS Management

The 100+ Chemical Challenge

When you have more than 100 chemicals on-site, paper-based SDS management breaks down:

• Finding the right SDS takes too long (critical during spills)
• Version control becomes impossible — are your SDSs current?
• Multi-building facilities need SDSs at every location
• Contractor access — outside workers need SDS access too
• Audits consume hours of preparation

Digital SDS Solutions for Manufacturing

Effective manufacturing SDS management requires:

1. Centralized database — All SDSs searchable from one system
2. Location-based organization — Group chemicals by building, line, or area
3. Role-based access — Different views for operators, supervisors, and EHS staff
4. Mobile access — Search and view SDSs from tablets on the production floor
5. Integration — Connect with existing EHS and inventory systems
6. Audit trail — Every SDS access logged with timestamps

Building an OSHA-Ready Program

1. Chemical Inventory Management

Maintain a master chemical inventory that includes:

• Chemical name and manufacturer
• Location(s) where stored and used
• Approximate quantities
• Date SDS was last updated
• Responsible department

Review the inventory whenever chemicals are added, removed, or substituted.

2. SDS Organization by Area

For large facilities, organize SDSs by work area in addition to a master database:

• Each department should know which chemicals are in their area
• Emergency responders need quick access to the most hazardous chemicals
• Receiving should check for SDSs when new chemicals arrive

3. New Chemical Approval Process

Before any new chemical enters the facility:

1. Obtain the SDS from the supplier
2. EHS reviews the SDS for hazards and compatibility
3. Verify adequate PPE and controls are available
4. Add to the chemical inventory
5. Train affected employees
6. Update the SDS database

4. Contractor Management

Outside contractors bring their own chemicals on-site. Your HazCom program must:

• Require contractors to provide SDSs for chemicals they bring
• Inform contractors about your hazardous chemicals they may encounter
• Ensure contractors know your emergency procedures

5. Employee Training Program

Manufacturing training should be:

• Job-specific — Welders need different training than assembly workers
• Chemical-specific — Focus on the chemicals each role actually handles
• Hands-on — Show employees where and how to access SDSs
• Documented — Records must include date, topics, trainer, and attendees
• Ongoing — Refresher training plus updates when new chemicals are introduced

Inspection Readiness

OSHA inspections in manufacturing often focus on:

• Random employee interviews — Can they explain the chemicals they work with?
• SDS accessibility — Can an employee quickly find any SDS?
• Written program — Is it complete, current, and site-specific?
• Container labels — Are all secondary containers properly labeled?
• Training records — Who was trained, when, and on what?

The best way to be ready for an inspection is to have a system you actually use every day — not one you scramble to prepare when OSHA is at the gate.

Measuring Safety Performance

Track these metrics to continuously improve:

• SDS completion rate — % of on-site chemicals with current SDSs
• Training compliance — % of employees with up-to-date HazCom training
• Chemical incidents — Spills, exposures, near-misses
• SDS access time — How quickly can any employee find any SDS?
• Audit findings — Trends in internal and external audit results

Multi-Site Considerations

Manufacturers with multiple facilities need:

• Standardized processes across all locations
• Centralized SDS database accessible from every site
• Consistent training materials and requirements
• Corporate oversight with local flexibility for site-specific chemicals
• Reporting rollups for corporate EHS dashboards