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HazCom Plan Builder

The HazCom Plan Builder enables companies to create, manage, and maintain OSHA-compliant Hazard Communication Plans (Written Programs) as required by 29 CFR 1910.1200.

Overview​

Every employer with hazardous chemicals in the workplace must have a written Hazard Communication Plan. The Plan Builder provides a guided, two-tier approach:

TierPlansDescription
BasicStarterTemplate-driven questionnaire with pre-written paragraph options. No AI.
PremiumStandard / ProAI-powered content generation, dynamic questions tailored to chemical inventory, auto-suggested answers.

Both tiers include full approval workflows, audit logging, version management, and PDF export.

Key Features​

Questionnaire-Based Plan Creation​

  • 7 OSHA-mandated sections covering all required elements of 29 CFR 1910.1200(e)
  • Section-by-section progress tracking with real-time completion percentage
  • Pre-written paragraph options for common compliance responses
  • Support for text, textarea, select, multi-select, yes/no, and date question types

AI Content Generation (Premium)​

  • AI Context: Gathers company profile, site info, chemical inventory, SDS coverage, and hazard classes
  • Dynamic Questions: AI generates tailored questions based on actual chemical inventory (e.g., specific handling procedures for flammable or corrosive chemicals on-site)
  • Auto-Suggested Answers: AI pre-fills answers using company data with accept/dismiss controls
  • Confidence Scoring: Each generated section includes a confidence score
  • SQS-Based Processing: AI operations run asynchronously via AWS SQS for reliability

PRO Auto-Setup Pipeline (Premium)​

When a premium plan is created, a multi-phase background pipeline automatically:

  1. Gathers company profile and site information
  2. Fetches chemical inventory with SDS data and hazard classifications
  3. Builds enriched regulatory context
  4. Generates dynamic questions tailored to the company's chemicals
  5. Pre-fills answers for both static and dynamic questions

Users see an animated progress overlay and are automatically transitioned to the questionnaire when setup completes.

Generate Plan​

  • Basic plans: Synchronous template-based generation from questionnaire answers
  • Premium plans: AI generates consultant-grade content using enriched context (company data + chemical inventory + all answers)
  • Requires 100% questionnaire completion before generation

Split View Editor​

After plan content is generated, users edit in a split view:

  • Left panel: Section tabs + monospace markdown editor
  • Right panel: Live-rendered HTML preview (updates on every keystroke)
  • Debounced auto-save to backend

Approval Workflow​

StatusActionsWho
DraftEdit, Generate Plan, Submit for ApprovalAny editor
Pending ApprovalApprove, Reject (with reason)Admin, Coordinator, Manager
ApprovedPublishAny editor
ActiveCreate New VersionAny editor
ArchivedCreate New VersionAny editor

Version Management​

  • Create New Version: Creates a new draft copy from any approved/active/archived plan
  • Copies all sections, answers, content, and metadata
  • Increments version number; original plan unchanged
  • Version history per site with timeline view

Editing Permissions​

  • Only draft status plans allow editing (questionnaire, content, metadata)
  • Non-draft plans return 403 Forbidden on edit attempts
  • "Create New Version" is the path to making changes on published plans

Audit Logging​

  • Dedicated plan_hazcom_audit_logs table with 16 action types
  • Action categories: general, section, workflow, export, version
  • Captures user ID, email, IP, user agent, plan version, and status
  • Company-wide and plan-specific log views with pagination and filtering
  • CSV export for compliance reporting

PDF Export​

  • Client-side PDF generation via jsPDF
  • Full document rendering with table of contents

OSHA Sections​

#SectionOSHA ReferenceCovers
1Company & Site InformationGeneralCompany name, site address, coordinator details
2Chemical Inventory§1910.1200(e)Inventory scope, storage locations, update frequency
3Container Labeling§1910.1200(f)Shipped container checks, workplace labeling, portable containers
4Safety Data Sheets§1910.1200(g)SDS location, access procedures, maintenance
5Employee Training§1910.1200(h)Training frequency, topics, competency verification
6Non-Routine Tasks§1910.1200(e)(1)(ii)Procedures for non-routine chemical tasks
7Contractor Coordination§1910.1200(e)(2)Multi-employer hazard communication

Implementation Status​

All 5 phases are complete:

PhaseFeatureStatus
1Basic Plan Builder (MVP)Complete
2Version Management & Audit LoggingComplete
3AI Content Generation (SQS-Based)Complete
4PRO Auto-Setup PipelineComplete
5Restructured Plan BuilderComplete

Future Enhancements​

  • Change detection alerts (inventory/personnel changes trigger review reminders)
  • E-signature integration for approvals
  • DOCX export alongside PDF
  • Cross-site plan cloning
  • Training auto-generation from plan content
  • Webhook notifications for plan events