Common PPE Issues and How to Solve Them

Personal Protective Equipment (PPE) is a workplace staple across industries, but it often comes with challenges. From poor fit to low user compliance, these issues can compromise both safety and productivity. Let’s talk about some frequent problems businesses face with PPE and practical ways to address them.

1. Fit Problems and Discomfort

Ill-fitting PPE is a top complaint. Gloves that pinch, goggles that fog up, or helmets that slide around can make workers hesitant to use them. Poor fit doesn’t just lead to discomfort; it can reduce effectiveness, putting users at risk.

Solution: Tailored Sizing and Adjustable Features

When purchasing PPE, opt for brands that offer a wide range of sizes and adjustable options. For instance, helmets with ratchet adjustment systems allow users to get a snug fit without over-tightening. Gloves with stretchable materials or size-specific molds reduce chafing and fatigue.

Consider having workers try on samples before placing large orders. This ensures the PPE matches the diversity of your team, addressing comfort and usability upfront.

2. Low User Compliance

Even the best equipment won’t protect anyone if it isn’t used consistently. Workers sometimes skip PPE because it’s cumbersome, hot, or seen as unnecessary for certain tasks.

Solution: Focus on Training and Feedback

A well-informed workforce is more likely to use PPE correctly. Hold hands-on training sessions that demonstrate how PPE can prevent injuries in real-life scenarios. Keep these sessions interactive and encourage questions.

Gather regular feedback from employees. If complaints about a particular piece of gear surface repeatedly, consider upgrading to more user-friendly options. Workers are far more likely to comply when they feel their concerns are heard and addressed.

3. Durability and Lifespan Issues

Some PPE wears out faster than expected, especially when used in demanding environments. Torn gloves, cracked face shields, or worn-out respirators can leave users unprotected.

Solution: Choose Quality Over Cost

While budget constraints are real, cutting corners on PPE quality often results in more frequent replacements—and higher long-term costs. Invest in equipment designed to withstand your specific workplace conditions.

Set up regular inspections to catch wear and tear early. Replace or repair damaged items immediately, and keep spare stock available to avoid delays. Some manufacturers offer warranties or maintenance plans; these can be worthwhile for high-use items like respirators or helmets.

4. Fogging and Visibility Problems

Fogging goggles, scratched face shields, and poorly ventilated helmets can obstruct vision, making tasks harder and more hazardous.

Solution: Look for Anti-Fog and Anti-Scratch Features

When purchasing eye and face protection, prioritize gear with anti-fog coatings or built-in ventilation systems. Some goggles even feature dual-pane lenses that resist fogging under extreme conditions.

Train employees to clean and store PPE properly to minimize scratches. For work environments with high humidity or temperature swings, invest in products explicitly designed for such challenges.

5. Compatibility Between Different PPE Items

Sometimes, PPE doesn’t work well together. For example, wearing earmuffs with a hard hat might compromise the fit of both, or goggles might interfere with a respirator’s seal.

Solution: Integrated Systems

Many manufacturers now design PPE systems where items are built to work together. Helmets with attachable face shields or earmuffs are a great example. Buying from the same brand often ensures better compatibility.

If an integrated system isn’t an option, test combinations of PPE during purchasing decisions. Involve workers in the process to ensure the final setup is both functional and comfortable.

6. Improper Storage

Improperly stored PPE can degrade quickly. Gloves left in direct sunlight, respirators tossed into toolboxes, or helmets stored near chemicals may become unusable faster than expected.

Solution: Designate a PPE Storage Area

Set up a clean, dry, and organized space for PPE storage. Use labeled bins, hooks, or lockers to keep items separated and easy to find.

For certain types of gear, like respirators, follow the manufacturer’s storage guidelines to preserve integrity. Remind employees to return items to the designated area after each use to prevent loss or damage.

7. Insufficient Protection for Specific Tasks

Generic PPE often fails to meet the unique demands of certain jobs. A worker handling hazardous chemicals might need gloves with a specific material resistance, while someone operating a chainsaw needs cut-proof gear.

Solution: Conduct Task-Specific Risk Assessments

Review the hazards associated with each job and match PPE accordingly. Partner with suppliers who can recommend products tailored to your industry.

Stay informed about innovations in PPE. Materials like Kevlar, nitrile, or advanced composites offer higher levels of protection and can often replace older designs that no longer meet standards.

8. Supply Chain and Availability Challenges

During periods of high demand or supply chain disruptions, obtaining enough PPE can be difficult. This was especially evident during recent global events.

Solution: Build Strong Supplier Relationships

Work with multiple vendors to avoid dependency on a single source. Keep an emergency stockpile for high-use items and monitor inventory levels closely.

Consider bulk purchasing agreements to lock in availability and pricing, especially for critical items. Communicate with suppliers about your needs to plan for future demand effectively.

9. Heat Stress and Overheating

PPE like coveralls, gloves, and helmets can trap heat, leading to discomfort or even heat-related illnesses during prolonged use.

Solution: Choose Breathable and Lightweight Options

Modern PPE often incorporates breathable fabrics or ventilation features to reduce heat buildup. Cooling vests and moisture-wicking materials can also make a significant difference for workers in hot environments.

Schedule regular breaks for employees to cool down and rehydrate. Providing shaded rest areas and access to water ensures safety while maintaining productivity.

10. Unclear Standards and Certifications

Not all PPE is created equal, and poorly labeled products can leave buyers unsure if the equipment meets regulatory requirements.

Solution: Verify Compliance Before Purchasing

Look for products that meet recognized standards, such as OSHA, ANSI, or ISO certifications. These standards vary by region and industry, so ensure you’re familiar with what applies to your workplace.

If you’re unsure, consult with safety professionals or trusted suppliers. They can help identify compliant equipment that fits your needs.

A Safer Workday, One Step at a Time

Dealing with PPE issues may seem like an ongoing challenge, but addressing these problems head-on leads to a safer, more productive work environment. Whether it’s ensuring better fit, improving durability, or finding ways to boost compliance, the key is to stay proactive and involve your team in the process.

The next time you face a PPE-related hurdle, remember: a little problem-solving today can save a lot of headaches—and hazards—tomorrow. Now, who’s ready to gear up and get back to work?