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OSHA 300 log workbook
An OSHA 300 log is the record an employer keeps of each work-related injury or illness that meets the recording rules in 29 CFR Part 1904, the part of the Code of Federal Regulations that covers OSHA recordkeeping. The 300A is the summary of that log for one calendar year. A company executive certifies it, and it is posted from February 1 to April 30 of the following year. This workbook lays the log out like Form 300, with the same columns A to L, the six injury and illness type boxes, and drop-downs for the X boxes. The Form 300A sheet totals itself from the log, and the Rates sheet works out the total recordable incident rate (TRIR) and the DART rate from your hours. A Recordable decision sheet takes one case at a time through the questions in 1904.4 to 1904.11 and answers Record it, Do not record or Check first. The PDF has a one-page decision guide with the section of the rule beside each step, a page on the three forms with dates and retention, and a page of sources. For records covering 2026, the 300A goes up by February 1, 2027 and stays up until April 30, 2027. The workbook is an aid. It is not an OSHA form and it is not legal advice.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
A flow of five boxes, covered, work-related, new case, meets a recording criterion and record it, each with the section of 29 CFR 1904, beside lists of the work-relatedness exceptions and the first aid treatments.Log laid out like Form 300Drop-downs for the X boxes180-day flagPrivacy case ruleRow check on every case300A that totals itselfTRIR and DART ratesHours and employees worksheetsIs it recordable? walkChecks sheetExample logDecision guide PDF
When to use it
When to use an OSHA 300 log workbook
- When you keep the 300 log in a spreadsheet and want the columns, the X boxes and the year-end totals to match the OSHA form.
- When you are not sure a case is recordable and want to go through the rule step by step before you decide.
- In January, when you total the year, check the log, and prepare the 300A for a company executive to certify.
- When you need TRIR and DART for a safety meeting or a customer questionnaire and want them worked from the same log the 300A uses.
- When you cover several plants as a consultant or corporate EHS lead and want one layout for every establishment's log, one workbook per site.
How to fill it in
- 1
Set up the year and the establishment
Type the calendar year, the company and establishment details, the NAICS code, the annual average number of employees and the hours worked on the Establishment sheet. The worksheets there help if you do not have the average or the hours.
- 2
Decide whether the case is recordable
Answer the questions on the Recordable decision sheet. It follows 1904.4: is the person covered, is it work-related, is it a new case, and does it meet a criterion in 1904.7 to 1904.11. Treat Check first as a stop sign and read the section.
- 3
Enter the case within 7 calendar days
One row on the Log: case number, name or privacy case, job title, date, where it happened, and a one or two line description. 1904.29(b)(3) gives you seven calendar days from learning of the case.
- 4
Classify it once
Choose X in only one of G to J, the most serious outcome, and in one injury or illness type. Enter days away in K and days of job transfer or restriction in L, counted in calendar days from the day after the injury.
- 5
Watch the flags
The 180-day flag and the row check beside each case catch the common slips as you type. The Checks sheet counts them: no classification, two classifications, duplicate case numbers, dates outside the year.
- 6
Total the year on the 300A sheet
Review the log, fix what Checks flags, then read the totals on Form 300A. A company executive certifies it. Print it, post it by February 1 and leave it up until April 30.
- 7
Work out the rates
The Rates sheet gives TRIR and DART. It shows the cases, the 200,000 base and the hours side by side, so you can check each rate by hand.
The 300A boxes
Where each 300A box comes from
Every box on the Form 300A sheet is a count or a sum of the Log, so nothing is typed twice. Each case sits in one of G to J only, the most serious outcome.
| 300A box | What it counts | On the Log |
|---|---|---|
| G Deaths | Cases with a work-related death | Count of X in column G |
| H Days away from work | Cases with one or more days away | Count of X in column H |
| I Job transfer or restriction | Cases with restricted work or a job transfer and no days away | Count of X in column I |
| J Other recordable cases | Recordable cases with none of those outcomes, for example medical treatment beyond first aid only | Count of X in column J |
| K Days away from work | Calendar days away, counted from the day after the injury | Sum of column K |
| L Days of job transfer or restriction | Calendar days on job transfer or restriction | Sum of column L |
| M (1) to (6) | Injuries, skin disorders, respiratory conditions, poisonings, hearing loss, all other illnesses | Count of X in each type column |
G Deaths
- What it counts
- Cases with a work-related death
- On the Log
- Count of X in column G
H Days away from work
- What it counts
- Cases with one or more days away
- On the Log
- Count of X in column H
I Job transfer or restriction
- What it counts
- Cases with restricted work or a job transfer and no days away
- On the Log
- Count of X in column I
J Other recordable cases
- What it counts
- Recordable cases with none of those outcomes, for example medical treatment beyond first aid only
- On the Log
- Count of X in column J
K Days away from work
- What it counts
- Calendar days away, counted from the day after the injury
- On the Log
- Sum of column K
L Days of job transfer or restriction
- What it counts
- Calendar days on job transfer or restriction
- On the Log
- Sum of column L
M (1) to (6)
- What it counts
- Injuries, skin disorders, respiratory conditions, poisonings, hearing loss, all other illnesses
- On the Log
- Count of X in each type column
A filled-in example
Illustrative, not a benchmarkAn example (illustrative): ten made-up cases at a fictional plant with 200 employees and 410,000 hours worked. The Example sheet in the Excel file holds them all. Every name, date and number is invented.
- Cases: 3 with days away (H), 3 with job transfer or restriction (I), 4 other recordable (J) and no deaths, so 10 recordable cases.
- Days: 196 days away (4 + 12 + 180) and 59 days of job transfer or restriction (10 + 21 + 20 + 3 + 5). One long absence is entered at the 180-day limit in 1904.7(b)(3)(vii).
- Types: 7 injuries, 1 skin disorder, 1 hearing loss and 1 other illness, which add up to the 10 cases.
- One of the ten is a privacy case, a cut from a sharp contaminated with another person's blood. Its row shows privacy case where the name goes.
- TRIR = 10 x 200,000 / 410,000 = 4.88. DART = (3 + 3) x 200,000 / 410,000 = 2.93.
The Example sheet also shows three decisions. A hand cut that is cleaned and covered with a bandage is first aid and is not recorded. The same cut closed with sutures is medical treatment beyond first aid and goes in column J. Back pain that started at home and does not get worse at work is not work-related. The numbers are made up to show the formulas, not a benchmark.
Common mistakes
Ticking more than one of G to J
Choose the most serious outcome only. A case with both days away and restricted days is column H, with days in K and in L.
Counting the day of injury
Days are counted from the day after, in calendar days. Weekends and days off count if the person could not have worked.
Getting first aid wrong
The first aid list in 1904.7(b)(5)(ii) is complete. Sutures, prescription-strength medicine and rigid supports are not on it, and a visit for observation, counseling or diagnostic tests alone is not medical treatment.
Putting a name on a privacy case
For the cases listed in 1904.29(b)(7), type privacy case where the name goes and keep a separate confidential list of case numbers and names.
Using the wrong hours
Hours worked leave out paid vacation, sick leave and holidays. A payroll figure that includes them understates the rate.
Sharing the file with names in it
The log holds health information. Employees and their representatives may see it with names. For anyone else, remove names and other identifying details first (1904.29(b)(10)).
Not updating a case
If a case gets worse or the outcome changes, change the entry, including the classification and the days (1904.33(b)(1)), not only a note.
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FAQ
OSHA 300 log workbook: common questions
OSHA allows equivalent forms: the same information, as readable and understandable, completed using the same instructions as the OSHA form (29 CFR 1904.29(b)(4)). OSHA's forms page says equivalent forms may be kept in any file format, Excel included, as long as that test and the 300A statement requirement in 1904.32(b)(2)(iii) are met. A computer system must be able to produce equivalent forms when they are asked for (1904.29(b)(5)). This workbook is laid out like the OSHA forms, but it is not an OSHA form, and whether it is equivalent for your establishment is your decision.
It covers one calendar year. Post it no later than February 1 of the next year and keep it up until April 30 (1904.32(b)(6)). For the 2026 records, that is February 1 to April 30, 2027. A company executive must certify it first. You post the 300A summary only, not the log. Keep the log, the privacy case list, the 300A and the 301 incident reports for five years following the end of the year they cover (1904.33(a)): for 2026 records, until the end of 2031, updating the log for newly discovered cases and changed classifications (1904.33(b)(1)).
TRIR = recordable cases x 200,000 / hours worked. DART = (cases with days away from work + cases with job transfer or restriction) x 200,000 / hours worked, which is boxes H and I of the 300A. 200,000 is the hours of 100 full-time employees working 40 hours a week for 50 weeks (OSHA's forms package and BLS). OSHA's worksheet adds columns H, I and J for the total, and BLS counts nonfatal cases, so deaths are shown on their own in the workbook.
The words privacy case, not the name. The cases are an injury or illness to an intimate body part or the reproductive system, a sexual assault, a mental illness, HIV infection, hepatitis or tuberculosis, a needlestick or a cut from a contaminated sharp, and another illness if the employee asks for the name to be left off. The list is complete. You keep a separate, confidential list of the case numbers and names (1904.29(b)(6) to (8)).
Not if your company had 10 or fewer employees at all times in the last calendar year, or the establishment is in an industry on OSHA's partially exempt list (1904.1, 1904.2). No manufacturing industry is on that list. Every employer must still report a death, in-patient hospitalization, amputation or loss of an eye (1904.39). Only three categories of establishment submit data every year (1904.41(b)(1)), by March 2 of the next year: those with 250 or more employees that must keep records, those with 20 to 249 employees in the industries listed in Appendix A to Subpart E, and, for the 300 and 301 as well, those with 100 or more employees in the Appendix B industries. Other establishments submit only if OSHA tells them to. State Plan states can differ.
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- Breakdown analysis reportOne equipment breakdown from the stop to the 90-day check, plus a breakdown log with repeat flags, MTBF and MTTR by asset and a Pareto of causes.
- Heijunka box planner (production leveling)Weekly demand turned into containers a day, takt, pitch and slots, a leveled sequence of products and the heijunka box, with a check that the changeovers fit.
- 4M change management sheet (change point)A shift log of every change to Man, Machine, Material, Method or Design, the extra checks after it and when normal checks resume, with a change point board.
- Future state value stream map worksheetThe eight future-state questions worked through in order: takt, pitch, flow, supermarkets, the pacemaker and the mix, with an EPEI check and current against future lead time.
- Value stream plan (VSM action plan)The future-state map cut into loops, each with an objective and a measurable goal, and its kaizen bursts turned into owned, dated projects on a 12-month timeline.
- Kaizen project plan (Gantt chart)One improvement project as a Gantt chart: tasks by phase with owners, predecessors and working days, a 16-week grid, milestones and a status from planned against actual % done.
- Histogram templateReadings, bins set by the square root rule, a tally and counts, the spec limits drawn and the share out of spec, with the common shapes explained.
- Scatter diagram templateUp to 50 pairs with a group code, r and R², the least squares line, the quadrant count and r for each group.
- Gauge calibration logA gauge register with next due dates and status, a calibration record with as-found and as-left readings, and the steps when a gauge fails.
- Escalation matrix templateWho is called for each type of issue and after how long, with severity rules, contacts and an escalation log.
- Quality alert formA quality alert to post at the line, a sign-off sheet for every shift, and a log of open, expired and closed alerts.
- Employee recognition program templateDesign a recognition program on one page, then run it: points per action, prizes, budget, a points ledger, a monthly leaderboard and a fairness check by team and shift.
- Lean transformation roadmapA plant-wide lean program on one sheet: six phases with exit criteria, six workstreams by quarter over 24 months, the model line, metrics with baseline and target, cadence and risks.
- Obeya room plannerPlan the walls, owners, cadence, agenda and rules of an obeya, then run the weekly review of KPIs, problems, actions and milestones.
- Paper forms inventory (paperless manufacturing worksheet)Every paper form, checklist and log in one list: hours a month, who acts on it, how long the paper waits, and which forms to move first.
- Continuous improvement software evaluation scorecardCompare CI software vendors: a must-have gate, eight weighted criteria scored 1 to 5, points out of 100 and a rank, with a demo script and reference questions.
- Lean principles assessment templateThe five lean principles as 25 things you can see on one value stream, answered yes, partly or no on a walk, with a score per principle, the next step and a trend over walks.
- Employee engagement survey templateA short anonymous pulse survey for shop floor staff: 14 statements in six drivers, two open questions, results by driver and team, and the actions.
- Hansei reflection sheet (lessons learned)A written look back at one finished project, event or launch: goals against results in numbers, causes rather than blame, lessons to keep or change, and where else they apply.
- Daily kaizen routine boardA team's 10 to 15 minute daily routine at the board: one problem from each person, small fixes with one owner, counted every week.
- Quality circle meeting recordA circle's charter, a one-page record for each meeting and a problem register that follows every problem from selected to closed or escalated.
- Weekly maintenance schedule templateNext week's maintenance jobs, scheduled only when ready, loaded against each craft's hours by day, with schedule compliance and break-ins at week end.
- Operational excellence assessment templateThe ten principles of operational excellence as 30 behaviors and practices you can see, scored 1 to 5 by several people, with the spread, the three lowest principles and an action plan.
- Scrum meeting agenda templateTimed agendas for the five scrum meetings, a sprint planning sheet, a retrospective sheet, and an Excel sprint backlog with a burndown.
- Toyota Production System (TPS) house templateThe TPS house for one plant or value stream: roof, two pillars and foundation, with what you do today, the evidence, a status and the next step for each element.
- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Autonomous maintenance 90-day model area planAM steps 0 to 3 on one model machine in 13 weeks, a KPI board, the day-90 gate and expansion waves for months 4 to 12.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Cost per unit worksheet (manufacturing cost per good unit)One product's cost per good unit by materials, labor, machine and overhead, the gap to target, and which cost lever is worth most a year.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- Energy use and EnPI trackerMonthly electricity, gas and fuel in one unit, a 12-month regression baseline, expected against actual energy for each month, an EnPI ratio, the running saving and the tests that say whether the model can be trusted.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.