OSHA Inspection: ALDI, INCORPORATED

Issued

Jan 16, 1991

Abate by

Oct 18, 1991

Penalty

Initial $1,000 · Current $700 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 required
to perform lifting tasks resulting in stressors that had caused, or were
likely cause musculoskeletal injuries:
a) Warehouse - Order selection. The evaluation of this manual lifting
task indicates that employees were exposed to a hazard which is
causing or likely to cause musculoskeletal injuries. The employer did
not implement an effective control strategy to reduce to eliminate
such injuries. The injury and illness records for 1989 and 1990
documented a pattern or musculoskeletal injuries.
b) Freezer/Cooler - Order Selection. The evaluation of this manual
lifting task indicates that employees are exposed to a hazard which
is causing or likely to cause musculoskeletal injuries. The employer
did not implement an effective control strategy to reduce or
eliminate such injuries. The injury and illness records for 1989 and
1990 documented a pattern of musculoskeletal injuries.
Among other methods, one feasible and acceptable abatement method to
correct this hazard is the implementation of an ergonomics management
program consisting of the following four elements:
1) Worksite analysis to recognize and identify existing manual lifting
hazards is the workplace. This analysis should include development
and use of an ergonomic checklist and employee questionnaire.
Periodic surveys of the workplace shall be conducted at least
annually to evaluate work practices and engineering controls.
Employee participation in the ergonomic program should be encouraged
through a mechanism such as a safety committee.
2) Medical management which includes accurate recordkeeping of manual
lifting injuries. The program should address early recognition,
evaluation and referral of lifting injury cases. Systematic worksite
review by the medical team should also be included in the program.
3) Training and education for exposed employees, including methods to
evaluate the effectiveness of the training. Re-training should be
done annually, or as operations change. Training should address
hazards associated with the job, the risks of manual material
handling, and how to prevent the lifting injuries. A supervisors'
training program should also be implemented to allow recognition
of manual lifting hazards and to reinforce the employer's ergonomics
program.
4) Hazard prevention and control which includes engineering, work
practice, and administrative controls.
a) Administrative controls are implements which reduce the duration,
frequency, and severity or exposure to manual lifting hazards. These
controls may include job rotation, reduction of repetitions, multiple
person lifts and preventative maintenance of related equipment.
b) Work practice controls are implemented which include proper work
techniques, new employee conditioning, proper placement of loads, and
reduction of weight lifted.
Examples of work practice controls applicable in this workplace
include:
i) Have the worker walk and carry the box/bag around the pallet rather
than building the pallet from the far side. This would allow the
worker to keep the load close to the body when liftinf or lowering
the load on the pallet. This would also reduce swinging the load and
large reaches which produce stresses on the musculoskeletal system.
ii) Eliminate picking from one side of the aisle and have the workers
pick from both sides of the aisel to accomplish the recommendation in
(i).
iii) Use a single pallet on the tugger when the on the tugger when the
order consists of heavier items.
iv) Repack or order heavy products into lighter loads as much as
possible.
v) Reduce intensity of picking and/or provide greater rest allowances
to reduce excessive fatique.
Worker's heart rate and/or oxygen uptake should be monitored to
determine physiological demands being placed on the order selectors
and to check whether the expected work rates are within physiological
acceptable limits. Based on the physiciological stresses, either the
work intenhsity should be reduced and greater rest allowances should
be provided.
vi) Workers need to be educated and trained in safe lifting procedures
and their lifting techniques should be periodically monitored.
c) Engineering controls are designed by a qualifed ergonomist and may
include work-station redesign, tool and handle redesign, and use of
mechanical lifting aids. The goal of this program should be to make
the job fit the person.
Examples of engineering controls applicable to this workplace include
i) Raise the storage height to 20", preferably 30", for all cases and
bags weighing more than 30 lbs. and for those that are most
frequently picked. These items should be stored between 20" and 58"
(shoulder height).
This would reduce bending while lifting heavy objects which is a
major risk factor for low-back pain.
ii) For objects in recommendation (i), provide 18" (shoulder width)
clearance on either side of the pallet in the aisles.
This would allow the worker to walk to the case in the back of the
aisle and keep the load close to the body while lifting by
approaching the case/bag from the side rather than from the front.
This would alos reduce twisting of the spine and lifting across the
body.
iii) Limit the number of cases per order so that the pallet load height
is below the shoulder height. Keep this height below the chest height
when the order consists of heavier items.
Step 1- Implementation of an ergonomics program for worksite analysis,
medical management, and training and education, as detailed in items
1-3 above.
Step 2- Submit to the Area Director a written, detailed plan of
abatement outlining a schedule for the implementation of the
administrative, work practice, and engineering controls as detailed
in items 4(a) - 4 (c).
ALL PROPOSED CONTROL MEASURES SHALL BE APPROVED FOR EACH PARTICULAR
USE BY A PERSON TRAINED IN THE EVALUATION OF WORKPLACE CONDITIONS
WHICH CAUSE MUSCULOSKELETAL DISORDERS.
SIXTY(60) DAY PROGRESS REPORTS ARE REQUIRED DURING THE ABATEMENT
PERIOD.
Step 3- Implementation of administrative, work practice, and engineering
controls, as described in items 4(a) - 4(c).