OSHA Inspection: SEALED POWER TECHNOLOGIES

Issued

Jan 24, 1991

Abate by

Feb 7, 1992

Penalty

Initial $1,000 · Current $500 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
employer did not furnish employment and a place of employment which
were free from recognized hazards that were causing or likely to cause
death or serious physical harm to employees in that employees were
exposed to:
(a) The hazard(s) of cumulative trauma disorder(s) due to re-
peated hand, arm and wrist exertions during repetitive tasks and
the resultant injurious effects of carpel tunnel syndrome, ten-
dinitis, numbness of hands and arms and shoulder sprains and
strains. Ergonomic evaluations were not performed to identify
and subsequently modify such operations to reduce worker expo-
sure.
(1) In the molding department, molding machine operators
were exposed to identified ergonomic risk factors, resulting
in the developmen of cumulative trauma disorders caused by
the repetitive tasks involved in the operation of the ma-
chines including the carrying and stacking of tote bins, man-
ual inspection and reaming of parts, and the use of sizing
bars for funnel shaped part.
(2) In the assembly department, assembly machine operators,
including those at work stations #104, #153, #741, chrysler
#604 and F100, were exposed to identified ergonomic risk fac-
tors, resulting in the development of cumulative trauma dis-
orders caused by the operation of single station and multiple
station/turntable presses and other repetitive tasks in-
volved. Additional stressors associated with this job in-
clude the carrying of tote bins and the use of improperly
sized hand tools.
Among other methods, feasible abatement methods shall include:
(1) Utilize ergonomic-engineering studies to identify the
worker job asignments which have a prevalence of cumulative
trauma disorders due to the repetitive tasks performed. De
termine appropriate engineering and/or administrative con-
trols to be implemented which will reduce the incidence of
cumulative trauma disorders.
(2) Develop a comprehensive education program which will
provide information and training to employees and management
regarding the general factors involved in cumulative trauma
disorders, work practices for the repetitive tasks which will
minimize the levels of mechanical forces applied and the num-
ber of repetitive motion patterns and the introduction to
work station and/or operation changes to be implemented.
(3) Improve the medical services program to provide evalua-
tion/examinations pertinent to worker medial nerve distribu-
tion and muscular aberrations. The data obtained may be used
to determine job assignment options for workers assigned to
perform repetitive tasks either before assignment or subse-
quent to surgical corrections.
(4) Implement the above controls and establish an ongoing
audit program to ensure the continued effectiveness of engi-
neering, administrative and work practice controls selected.
Emphasis shall be placed on the following ergonomic aspects
identified as applicable to the operations listed above:
(1) Molding department:
(a) Removal of metal sizing bars (used for the moldings
which have funnel type openings) from the edge of the
work tables when not needed, and utilize cushioned edges
for worker arm/elbow support(s).
(b) Use of ergonomically designed workstations which
include adjustable chairs equipped with back, seat and
foot supports to provide proper postural support to the
back, legs and shoulders. Ensure adequate clearance is
provided for the operator(s) legs and thighs under the
work table.
(c) Modify the handles provided on the tote bins to
provide a contoured gripping block or cut out and allow
workers to use a hook grasp rather than a finger grip.
(d) Implementation of work practice controls to limit
the stacking of tote bins containing parts/materials so
that the operator(s) do not lift above the shoulder and-
/or provide combination roller conveyor/hydraulic table
which would allow the operator(s) to keep the bins at
the proper height for stacking.
(2) Assembly department:
(a) Evaluate the height of overhead two-hand controls
used to operate presses #5, #213 and the press used for
the 604 Chrysler subassemblies, to limit the operator(s)
stretching their shoulders and arms above shoulder
height to initiate the cycle. (Control location must
meet the requirements of 1910.217 (c) for safe distance
requirements.) Continue with the modification of press
2-hand controls from palm buttons to light beam con-
trols.
(b) Redesign the tool used for the manual spreading of
glue on the 153 filter assembly line to reduce the flex-
tion to the operator(s) wrist, pressure applied to the
index finger and lateral extension of the elbow. As an
interim measure, provide the workers with glue spreader
tools that allow the spreading to be performed while the
workers hand and wrist are in the neutral position.
Provide a powered turntable that will rotate the metal
filter pieces under the workers hand that performs the
spreading.
(c) Modify the dispensing port for the automatic glue
application on the 153 filter assembly line so that it
will spread the glue into the rexessed well of filter
assembly and eliminate the need to manually spread the
glue.
(d) Modify the stacking shelves on presses #45, #41,
#5, 153 and 741 assembly stations so that components for
the parts to be assembled are at an angle to reduce the
degree of flexion to the wrist when retrieving com-
ponents. Positioned heights and angles should allow
workers to handle materials with shoulder ectension
angles of 45 degrees or less.
(e) Develop a schedule which limits the number of work
hour and/or maximum number of cycles at those stations
which have been identified as having tasks involving a
high degree or ergonomic risk factors.
(f) Implement the use of ergonomically designed work
stations which include adjustable chairs equipped with
back, seat and foot supports to provide proper postural
support to the back, legs and shoulders. Ensure that
adequate clearance is provided for operator(s) legs and
thighs under the worktable/worksurface.
(g) Modify the handles on the tote bins used to carry
components and finished products to provide a contoured
gripping block, cut out or other arrangement which will
allow the use a hook grasp rather than a finger grip.
(3) Both Assembly and Molding departments:
(a) Ensure the use of highly flexible proper fitting
gloves. Offer gloves with high friction surfaces. The
combination of proper fit and high friction gloves re-
duces the hand/finger grip forces that workes need to
exert when performing tasks.
ABATEMENT SCHEDUEL
Step 1 - Submit to the Area Director a written detailed plan of abate-
ment outlining a schedule for the implementation to control
employee exposure to undue rekpetitive motion trauma as refer-
enced in this citation. This plan shall include at a minimum,
target dates for the following:
(a) Evaluation of the extent and cause of the hazard.
(b) Evaluation of control measure options.
(c) Selection of optional control measure(s).
(d) Determination of control measure design.
(e) Ordering and delivery of equipment and materials.
(f) Installation of control measure(s).
(g) Training of employees in proper operation and maintenance
of control measures and procedures, and
(h) Assurance of effective performance of such control mea-
sures and procedures.
Step 2 - Correction shall be completed by the implementation of such
measures and procedures and their effectiveness at achieving
compliance verified.

Issued

Nov 5, 1990

Abate by

Nov 9, 1990

Penalty

Initial $80 · Current $80