Near misses are often dismissed as “close calls,” moments where nothing bad happened and work continued as usual. But in reality, near misses are some of the most valuable safety data an organization can have.
Every serious injury, fatality, or catastrophic event is usually preceded by dozens—sometimes hundreds—of near misses. When those warning signs are ignored, organizations lose the opportunity to prevent incidents before someone gets hurt.
Understanding which near misses matter most—and why they should never be overlooked—is a critical part of building a proactive safety program.
What Is a Near Miss?
A near miss is an unplanned event that did not result in injury, illness, or damage—but had the potential to do so.
Examples include:
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A forklift narrowly missing a pedestrian
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A load shifting but not falling
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A slip without a fall
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A tool falling just short of striking someone
According to the Occupational Safety and Health Administration (OSHA), near misses are considered leading indicators of safety performance and should be treated as early warnings, not lucky escapes.
OSHA Safety Management Guidelines
Why Near Misses Are Often Ignored
Despite their importance, near misses frequently go unreported or unaddressed.
Common reasons include:
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“No one got hurt”
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Fear of blame or discipline
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Belief that reporting takes too much time
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Normalization of risk
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Lack of follow-up after past reports
The National Institute for Occupational Safety and Health (NIOSH) emphasizes that organizations with strong reporting cultures experience fewer serious incidents because hazards are addressed earlier.
Common Near Misses That Should Never Be Ignored
Some near misses are more predictive of serious incidents than others. The following categories consistently appear in OSHA citations, DOT investigations, and serious injury reports—and should always trigger review and corrective action.
1. Slips, Trips, and Loss of Balance
A stumble that doesn’t end in a fall is still a near miss.
Common examples:
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Tripping over cords, hoses, or debris
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Slipping on wet or oily surfaces
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Uneven walking surfaces or damaged flooring
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Temporary obstructions in walkways
Why it matters:
Slips, trips, and falls remain one of the leading causes of workplace injuries across industries, including warehousing, construction, and transportation facilities.
Near misses in this category often indicate:
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Poor housekeeping
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Inadequate lighting
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Inconsistent floor maintenance
2. Struck-By and Caught-Between Close Calls
Near misses involving moving objects or equipment should never be dismissed.
Examples include:
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Tools or materials falling from height
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Equipment swinging unexpectedly
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Hands or clothing nearly caught in machinery
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Loads shifting during lifting or transport
Why it matters:
Struck-by and caught-between hazards are frequently associated with serious and fatal injuries, especially in construction, manufacturing, and industrial settings.
Even when no injury occurs, these near misses often point to:
- Improper securing of materials
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Inadequate guarding
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Unsafe positioning or body mechanics
3. Equipment or Vehicle Near Collisions
Near collisions are among the most critical warning signs—especially in transportation, warehousing, and yard operations.
Examples include:
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Forklifts narrowly missing pedestrians
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Vehicles backing without spotters
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Near sideswipes in yards or terminals
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Close calls during coupling or docking
Why it matters:
The Federal Motor Carrier Safety Administration (FMCSA) and Department of Transportation (DOT) identify vehicle-related incidents as a leading cause of workplace fatalities.
Near misses in this area often indicate:
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Blind spot issues
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Inadequate traffic flow design
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Distraction or fatigue
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Insufficient backing or spotter procedures
4. Lockout/Tagout Failures That “Didn’t Cause Harm”
A piece of equipment unexpectedly starting—but not injuring anyone—is still a serious near miss.
Examples include:
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Equipment energizing during maintenance
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Incomplete lockout steps
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Lockout devices applied incorrectly
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Assumptions that equipment was de-energized
Why it matters:
Lockout/Tagout violations are consistently among OSHA’s Top 10 most cited standards, and failures often result in amputations or fatalities.
OSHA Lockout/Tagout Standard (29 CFR 1910.147)
Near misses here signal:
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Training gaps
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Procedural confusion
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Overreliance on experience instead of process
5. Improper Use or Absence of PPE
A near miss involving PPE—such as debris missing an unprotected eye—should always be investigated.
Examples include:
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Not wearing required PPE
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PPE worn incorrectly
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Damaged or poorly fitting PPE
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Temporary removal during tasks
Why it matters:
Personal Protective Equipment is often the last line of defense. When PPE nearly fails, it means other controls may already be insufficient.
Ignoring these near misses reinforces unsafe shortcuts and normalizes risk.
6. Chemical, Spill, or Exposure Close Calls
Chemical near misses are especially dangerous because health effects may not be immediate.
Examples include:
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Minor spills that are quickly cleaned
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Incorrect chemical handling
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Improper labeling or storage
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Near exposure to vapors or splashes
Why it matters:
NIOSH and OSHA both stress that repeated low-level exposures and near misses can contribute to long-term health issues.
Near misses in this category often reveal:
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Gaps in hazard communication
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Inadequate training
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Missing or outdated SDS access
7. Fatigue-Related Errors and Close Calls
Fatigue-related near misses are often overlooked because they don’t involve a visible hazard.
Examples include:
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Almost missing a step
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Nearly backing into an object
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Slower reaction times
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Momentary lapses in attention
Why it matters:
DOT and FMCSA research shows fatigue and distraction significantly increase the likelihood of preventable incidents—especially in safety-sensitive roles.
Near misses linked to fatigue signal the need for:
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Scheduling reviews
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Awareness training
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Early intervention strategies
Turning Near Misses Into Prevention Tools
Near misses are only valuable if they lead to action.
Effective safety programs:
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Encourage reporting without blame
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Actively review trends
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Share lessons learned
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Implement corrective actions promptly
OSHA emphasizes that near miss reporting should be part of a proactive safety and health management system, not a disciplinary tool.
Building a Culture That Takes Near Misses Seriously
Organizations that successfully reduce serious incidents treat near misses as:
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Learning opportunities
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Early warnings
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Indicators of system gaps
They focus on:
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Psychological safety
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Leadership follow-through
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Consistent communication
When employees see that reporting near misses leads to real improvements—not blame—participation increases, and risk decreases.
Final Thought
Near misses are not signs of good luck—they are signals of unfinished safety work.
Organizations that pay attention to near misses gain insight before injuries occur, reduce risk proactively, and build stronger safety cultures over time.
Sentry Road can support organizations in improving near-miss awareness, training, documentation, and follow-through across their safety programs.