Personal protective equipment (PPE) is one of the most basic — and most visible — elements of workplace safety. Helmets, gloves, goggles, high-visibility vests, respirators: these are often the last line of defense between workers and serious injury. Yet despite its importance, PPE is also one of the most commonly misused safety tools. From wearing it incorrectly to skipping it altogether, mistakes with PPE put employees at unnecessary risk. The good news? With the right awareness and approach, most of these mistakes are easy to fix.
Some employees skip PPE because it feels uncomfortable, unnecessary, or slows them down. Others simply underestimate the risks of the task at hand.
The Fix: Leaders must set the tone by wearing PPE themselves and enforcing its use consistently. Training should emphasize not just what to wear, but why it matters — connecting PPE to real-life incidents or near misses so employees understand the stakes.
Not all gloves, goggles, or masks are created equal. Wearing cut-resistant gloves while handling chemicals, or dust masks instead of respirators, leaves workers unprotected.
The Fix: Match the PPE to the hazard. Conduct proper risk assessments and ensure employees are trained to identify which equipment is right for each task. Supervisors should double-check compatibility before work begins.
Even when PPE is provided, it’s often worn the wrong way. Examples include helmets with unfastened chin straps, hearing protection worn loosely, or respirators not sealed properly.
The Fix: Practical, hands-on training is key. Employees should practice fitting and adjusting their PPE until it becomes second nature. Toolbox talks and refresher sessions can reinforce correct use.
Damaged, dirty, or expired PPE doesn’t provide full protection. Gloves with holes, scratched safety glasses, or old harnesses can give a false sense of security while still exposing workers to danger.
The Fix: Establish a routine inspection and replacement program. Teach workers to check their PPE before each use and encourage them to report damage immediately. Employers should make replacements easy and accessible.
Relying solely on PPE while ignoring other safety measures is a major mistake. PPE should be the last line of defense after hazards are eliminated or reduced through engineering or administrative controls.
The Fix: Reinforce the hierarchy of controls. PPE is important, but it should complement — not replace — safer equipment design, proper procedures, and effective training.
Fixing PPE mistakes isn’t just about correcting individuals. It’s about creating a culture where wearing and maintaining PPE is the norm. That means:
When workers understand the “why” behind PPE, and when leaders reinforce its use through example and support, compliance becomes second nature.
PPE may seem simple, but mistakes in its use can have life-changing consequences. By addressing common errors — from skipping equipment to wearing it incorrectly — companies can strengthen their last line of defense and keep workers safe. The fix isn’t complicated: provide the right gear, train employees on its proper use, and build a culture where safety comes first. Because at the end of the day, PPE only works when it’s used correctly, every single time.
