OSHA Inspection: ALCOA BUILDING PRODUCTS INC.

Issued

Oct 20, 1993

Abate by

Oct 14, 1994

Penalty

Initial $2,625 · Current $2,625

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:
Employees in department 456 were exposed to excessive ergonomic
stress caused by
repetitive motions associated with manipulation, packaging and
stacking of vinyl siding
and making boxes on the extrusion lines.  The repetitive motions
associated with the
extrusion line tasks caused, aggravated, or precipitated carpal
tunnel syndrome, wrist
tendinitis, wrist strain, wrist tenosynovitis, epicondylitis,
shoulder tendinitis, and
shoulder ligamentous and muscular strains.
Workers exposure to ergonomic stresses while performing extrusion line
tasks were shown by
a recorded history of worker lost and restricted time and symptoms of
pain
in the shoulders,
elbows, arms, wrists, and hands.
To reduce the ergonomic stresses resulting in injuries and illnesses to
employees performing
extrusion line packing, the employer shall develop, and implement a
complete ergonomic
program that includes, but is not limited to, the following:
1.   JOB STRESS ANALYSIS
Conduct an analysis of all the tasks performed by employees working
as extrusion
associates.  The ergonomic analysis shall include anthropometry,
posture force and the
frequency of actions, as well as the time between actions, and shall
utilize survey tools,
including videotaping of tasks and input from the employees whose
jobs are being
evaluated and videotaped.  Testing and evaluation of modifications
designed to reduce
the ergonomic stressors identified through the ergonomic analysis
should be performed.
During the testing and evaluation, input from the first line
supervisor and employees who
perform the jobs being studied should be obtained and considered.
2.   HAZARD PREVENTION AND CONTROL
Investigate and implement control measures that could include, but
are not limited to,
the following:
a.   ENGINEERING CONTROLS
1.   Change box to an open type instead of the tube type.
2.   Suspend the siding cutters from a tool balancer mounted on
a trolley to
reduce wrist, arm, and shoulder stress caused by the
operator holding the
tool to cut the scrap siding.
3.   Develop a box holder/box-bending fixture that the workers
can use while
making boxes.  The goal shall be that the folding fixture
will
allow faster
uniform folding, and having done it, will hold the box in
position for the
employee.
4.   Suspend the stapler.  Establish neutral wrist positions
for stapler use.
There may be a need to use both in-line and pistol-grip
staplers.  The
generally accepted use is in-line handle for work on
horizontal surface;
pistol-grip handle for work on vertical surfaces.
5.   Find a glue applicator so that (if needed) the worker does
not have to
squeeze and manipulate it to place the glue.
6.   For open sided box filling use a holder that the worker
can stack 4-8
pieces of siding onto.  The holder would be
counter-weighted and the
worker could use it to set the batch of siding pieces into
the box.
7.   Closed sided boxes:
a.   Establish the siding size and number of pieces that
shall be used
with each box size.  Sizing shall be consistent to
allow box filling
without prying or pressure forces.  When filled, the
siding might
be expected to have 1/2 inch on the sides and an
estimated 3/4 inch
or open space on the top.
b.   Drop the far end of the opened box to the floor.
Retain the front
end of the box at the level of the packing table.
The siding pieces
can then be slid into the box using gravity to assist
the fill.
c.   Use a fixture located at the far end of the table.
Stack 4-8 pieces
into the fixture.  The fixture needs to be
counterbalanced
and set
to deliver the 4-8 pieces in one movement.
8.   Use the Worker Questionnaire survey to establish the
individual stressful
elements of the job.  Pay particular attention to the
information provided
by workers who report joint pain.
9.   Noting a problem with excess flashing along the sides of
extruded product,
consult with the corporate engineers on the use of powered
roll slitters
positioned at the end of the extruder to cut off the
flashing.
10.  Use the NIOSH 1991 Lifting Guide to develop and evaluate
options for
lifting, handling, and stacking filled siding boxes onto
pallets.  Also be
aware that excess arm and shoulder extensions are likely
related to worker
elbow and shoulder pain.
b.   WORK PRACTICE CONTROLS
1.   Use conditioning period for employees newly assigned to
the extrusion line
so they are gradually integrated into the full workload.
2.   Provide frequent rest periods to relieve fatigued
muscle-tendon groups.
c.   ADMINISTRATIVE CONTROLS
1.   Increase the number of workers on the extrusion line so
that each
employee has more time to perform the different duties.
2.   Rotate employees on the line throughout the shift to
relieve upper
extremity stress from the packing, placing boxes on skids,
and making
boxes.
3.   Rotate employees off the extrusion line onto jobs that do
not
stress the
same muscle-tendon groups.
d.   MEDICAL MANAGEMENT
Establish a series of programs aimed at securing medical
identification and
treatment of workers' ergonomic injuries and illnesses that
include but are not
limited to the following:
1.   Monitor new and CTD damaged workers.  Determine whether
they are
performing tasks using the company prescribed methods,
practices and
workplace configurations.  Periodically review the
performance with the
worker, supervisor, safety and health personnel and the
medical staff.
2.   Encourage workers to advise company management as to on
the job
injuries and repetitive motion disorder symptoms they
experience,
as soon
as possible, so medical intervention can take place.
3.   In coordination with the injured worker's doctor, after an
injury or illness,
provide work that is consistent with the worker's
capabilities.
e.   TRAINING AND EDUCATION
1.   Assure training of managers, supervisors, and engineers to
develop
awareness of ergonomic hazards and to supply techniques
that may be used
to remedy stressors.
2.   Ensure a training program that instructs workers in the
proper method for
lifting and moving materials and recognition of neutral
postures for the
body to avoid repetitive motion or cumulative trauma
disorders.  Train
workers to use minimum stress methods for task performance
and
enforce
its use.
DISCLAIMERS
1.   You are not limited to the abatement methods suggested above.
2.   The methods explained are general and may not be effective in all
cases.
3.   The employer is responsible for selecting and carrying out an
appropriate abatement
method.