When PPE Isn't Used Correctly: How to Spot & Fix Compliance Gaps

Introduction:

Think of a workplace where safety gear is present, but workers still get injured due to misuse, neglect, and misunderstanding of the PPE. A more recent 2025 study by J. J. Keller & Associates Inc. and the International Safety Equipment Association (ISEA) highlights concerns regarding PPE compliance, reporting that more than 75% of safety professionals have challenges getting employees to wear PPE. In 2024, an experienced employee at a hectic factory plant was severely injured in his hand when a frayed glove became entangled in heavy equipment. Although familiar with PPE procedures, the employee had used defective gloves during a chaotic shift. The injury involving several surgeries and extensive rehab uncovered a trend of PPE indifference at the factory and prompted management to correct core safety concerns. These examples highlight the concerning trend of compliance gaps in the industries that risk the lives and livelihoods of employees. As we move forward, we must understand how to identify and address such gaps more than ever. In this blog post, we will cover the common signs of PPE non-compliance, the root cause of compliance gaps, and strategies to fix compliance issues.

What are the Common Signs of Improper PPE Usage?

PPE is adequate only when used correctly. Using PPE improperly develops a false sense of security, leaving workers exposed to hazards. So, it is essential to spot the signs of PPE issues before they escalate to injuries and violations. The following are the most common issues that indicate misuse of PPE at the workplace:

1. Removal and Modification of PPE by Workers
   Most workers remove the PPE to perform the job faster or alter it to feel comfortable. They cut the straps, wear respirators and other PPE loosely, and don't fasten the safety harnesses. Although these modifications might seem minor, they reduce the effectiveness of the PPE and expose the employees to avoidable risks.
2. Damaged PPE
   A worn-out and damaged PPE is as useless and dangerous as the absence of PPE. Protection is compromised due to cracked helmets, scratched safety glasses, and ripped gloves. 
3. Incorrect Donning of PPE
   Workers unsure when PPE is needed and how to wear it properly will either wear it incorrectly or skip it altogether. Take an example of a loosely fit respirator, incorrectly inserted earplugs, and hard hats worn backward, which suggest a lack of knowledge about the correct use of PPE. The lack of onboarding training causes this issue, as well as the absence of refresher training and communication gaps between employees and higher management.
4. Poor Storage & Maintenance of PPE.
   The PPE can quickly lose its protective properties if not properly stored. It includes tossing PPE on dirty surfaces, exposing the PPE to extreme heat, and storing it in shared bins without sanitizing it. Poorly stored PPE leads to Mold growth, contamination, and untimely wear, particularly in safety gloves and respirators. The lack of knowledge of how to clean, inspect, and store PPE makes the correct use of PPE less likely, putting everyone at risk.
   PPE compliance is about PPE availability, awareness, consistency, and accountability of PPE use. By identifying the warning signs of noncompliance with PPE and fixing the underlying root causes, the organizations can seal the compliance gaps and make sure the PPE performs its job, protecting the workers.

What are the Root Causes Behind PPE Non-Compliance

Consistent misuse and neglect in PPE use is more than a personal choice; it reflects the systematic gaps in training, culture, and communication. Digging deeper to find the root causes behind the compliance failure is the best way to fix them in the long run. The following are the major causes of the gaps in PPE compliance:

1. Lack of PPE usage Training:
   Lack of proper training about the importance of PPE and its correct use is the root cause of PPE misuse. Most businesses provide basic PPE training, especially during onboarding, but rarely reinforce it regularly. That is why In-depth training paired with ongoing refresher training is needed so that workers may remember the essential details.
2. Poor Supervision and Unclear Policies:
   Managers and supervisors who fail to enforce PPE rules consistently cause compliance gaps in PPE use. Similarly, vague and open-ended policies leave workers to keep guessing.
3. Lack of Safety Culture and Resistance from Workers:
   In companies where safety is treated as a tick box to check rather than a core value, the employees are likely to take PPE non-seriously. They may perceive using PPE as unnecessary, uncomfortable, and an obstacle to efficiency.
4. Broken or Unavailable PPE:
   If the PPE at the workplace is not accessible, then even the most well-trained workers can't use it properly and follow the protocols. Issues such as the gear being locked away, uncomfortable PPE, and a lack of required sizes cause workers to hesitate to use it. That's why PPE should be easily accessible and comfortable to encourage consistent use.
5. Language and Communication Barriers:
   In workplaces with diverse teams, language differences and literacy levels can also cause workers to not understand PPE requirements completely. Training, signage, and instructions not provided in employees’ native languages can also cause an untrained workforce and noncompliance. That is why it is essential to have multilingual training materials and signage to aid in bridging communication gaps.
6. Inconsistent Use of PPE across the Departments and Shifts:
   If the PPE is being used inconsistently across shifts, employees, and departments, it is due to the lack of standard enforcement and discrepancies in the training. For example, the morning shift at a workplace may follow the PPR protocols strictly, but the night shift slacks in the PPE use. This inconsistency is the cause of a lack of safety and erodes the trust in the safety culture as a whole.

What are the Hidden Risks of Misused PPE?

PPE is a worker's last line of defence to prevent serious injuries. But what happens if it is not worn correctly, misused, or not used entirely? The answer is that lacking the last layer of protection can lead to life-threatening consequences. Take the example of a construction worker who doesn't wear a fall protection harness, falls from heights, and gets fatally injured. Welders not wearing proper eye protection can get intense eye injuries from sparks and intense light. Similarly, workers who are exposed to hazardous chemicals without wearing gloves or respirators can have chemical burns, respiratory tract damage, and long-term health complications. 

There is no point in heavily investing in PPE if employees are not taught to use it properly. The lapses in PPE use can lead to dangerous blind spots, causing an increased risk of injury, death, and even financial repercussions. For example, a manufacturing plant got cited by OSHA and received hefty fines after many incidents where employees had to undergo hand amputations due to a lack of machine guards and gloves. The company also faced damages to its reputation, lost client trust, and increased insurance premiums. The worst part is that the PPE misuse goes unnoticed until the incident happens. So, in short, the misappropriation of PPE is not only an issue for workers but also an issue with leadership and the system that needs prompt attention. Not enforcing the proper PPE causes life loss, regulatory citations, huge financial liabilities, and penalties that can cause long-lasting damage to the company's reputation.

How to Improve PPE Compliance? 

Fixing PPE compliance gaps is not simply a disciplinary action; it needs a proactive and supportive approach that empowers the workforce and strengthens overall safety. The following are some practical steps to enhance PPE compliance and develop lasting safety habits:

1. Perform Routine Audits and Spot Checks:
   Regular inspections and unannounced inspections help identify real-time PPE misuse and compliance patterns. PPE audits are helpful in correcting the improper use of PPE within the safety teams and reinforcing the expectations of management. It also helps gather data to improve future training and resource allocation. Keeping a record of these results and findings is helpful in due diligence for regulators.
2. Execute the specific PPE-Training Programs:
   In addition to the general safety training, the management should provide targeted training sessions focused on PPE only. PPE-specific training should include topics such as correct PPE selection, donning and doffing PPE, limitations of PPE, maintenance, and proper disposal. The training should consist of interactive formats such as quizzes, real-life scenario-based lessons, and demonstrations to help improve knowledge retention. In addition to this, regular refresher training is also helpful.
3. Invest in Supervisors and Managers:
   Frontline leaders create the atmosphere. The managerial position holders should have the authority and tools to educate the employees on proper PPE use, conduct safety talks, and persistently enforce the policies. Among the employees, designate one as a safety champion to establish accountability and peer-to-peer influence. This is because workers tend to take reminders from their colleagues more seriously. 
4. Use Signage, Reminders, and Secure Access to PPE:
   In high-risk areas, visual signage and cues such as floor markings, posters, and digital displays act as a constant reminder. Similarly, PPE should be efficiently available at the point-of-use stations to reduce friction. Workers are more likely to use visible and accessible PPE. Also, ensure signage is multilingual and contains clear visuals for diverse employees.
5. Include Workers in PPE Selection and Feedback:
   When workers have an intake in the PPE selection, depending on the comfort, fit, and task relevance, they are more likely to wear it. Conduct surveys of employees and PPE fit-testing sessions, and get feedback on new PPE and equipment for continuous process improvement. Communicating concerns about the poor design or discomfort aids in eliminating the resistance and develops a sense of ownership among the workers regarding safety.
6. Motivate Compliance Through Positive Reward:
   Consistent PPE compliance should be rewarded by giving employees shoutouts and small incentives. Safety first culture should be celebrated, not just enforced, and that can be done only through positive reinforcement. This method is particularly efficacious in the high-turnover industries where it is challenging to develop long-term safety habits.

The Wrap-Up:

PPE is adequate only when used correctly. Workers' noncompliance regarding PPE use is not just negligence; it indicates that something deeper needs fixing. Unclear policies, gear that causes discomfort, and weak enforcement of policies; each such gap is a way to improve. As a safety leader, you must reframe the narrative from reactive enforcement to proactive engagement. It includes spotting signs of PPE noncompliance, understanding the primary cause, and implementing empowering strategies in the workforce. At the end of the day, compliance isn't the only goal; protection and trust will send every worker home safely.

References:

Cleaning and Maintenance Management, March 31, 2025, PPE Compliance Issues Persist, Study Finds, https://cmmonline.com/news/ppe-compliance-issues-persist-study-finds