OSHA Inspection: QUALITY ASSISTANCE CORP

Issued

Jun 29, 1989

Abate by

Aug 7, 1989

Penalty

Initial $640 · Current $400 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The
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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
the hazard of being caught in or crushed during the cleaning and
sanitizing of equipment such as the hog head table spike conveyor,
augers, blenders, mixers, etc.
On or about June 2, 1989 at FDL Foods, Rochelle, Il the employer,
Quality Assistance Corporation did not have an implemented lock out
program to de-energize electrical power sources and reducing the hog
head table spike conveyor to zero mechanical state during cleaning
and sanitation process.
Among other methods, one feasible and acceptable method to correct
these hazards is to establish administrative controls and procedures
over the work being performed which will instruct workers in the
recognition of these hazards; ensure safe shut down of machinery and
equipment by blocking, stopping or otherwise reducing to a zero
mechanical state.
Specific elements of the abatement program shall be expected to include,
but not necessarily be limited to:
1) Establish a comprehensive written procedure for lock-out which
includes procedures designed to instruct and train employees in
recognition of hazards and proper lock-out procedures.
2) Require lock-out before any maintenance, inspection, clearing,
adjusting or servicing that requires employees to enter on be in
close contact with machinery or equipment.
3) Maintain available operation and maintenance manuals on all
machinery or equipment, Assure that these manuals and other
appropriate information are provided to employees before work
is begun.
4) Establish and use a documented work order system which includes
Supervisors' approval to reactivate machinery or equipment.
5) Disconnect or isolate machinery or equipment by positioning the
switch, valve or other energy isolating device so that all energy
sources (e.g. electrical, mechanical, hydraulic, etc.) are
deactivated. Stored energy such as that in capacitors, springs,
elevated machine members, rotating flywheels, hydraulic systems and
gas, air, steam or water pressure, etc., must be dissipated or
restrained by methods such as grounding, repositioning, blocking,
bleeding down, etc.
6) Require that each exposed employee lock-out the energy isolating
device with his/her personal lock.
7) Test machinery or equipment to ensure that the energy sources have
been effectively disconnected or isolated. As a precautionary
measure, return the operating controls to the "OFF" position after
the test has been completed. NOTE: The test shall only be performed
after ensuring that no employees are exposed in the machine or
equipment area.
8) Remove locks only after ensuring the safety of all exposed
employees.
9) Train employees responsible for machinery or equipment lock-out in
all elements of the program. This training shall be repeated as
frequently as necessary to maintain management and work proficiency
and compliance with the procedure.
10) Evaluate the program periodically to ensure continued use  and
adequacy.
11) Enforce all provisions of the program.