OSHA Inspection: COLUMBUS AUTO PARTS

Issued

Apr 4, 1989

Abate by

Apr 17, 1989

Penalty

Initial $800 · Current $560 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) Forge Shop Area, and employee was adusting the dies of the National
Upsetter Machine, Unit 23 Serial Number 246594, without first
employing a positive means of locking out the machine.
Abatement of the hazard can be accomplished by the establishment of
management controls over the work being performed, instruction of
workers in the recognition of hazards, safe shut down of machines,
blocking, stopping and reducing machines to zero Mechanical Energy
State (ZMS) documentation of maintenance performed. Specific elements
of the abatement program shall be expected to include, but not
necessarily be limited to:
-At the start of work, switch off and use a worker individual lock on
the electric switch to prevent re-energizing the machine.  After
switch off, assure that the electric circuits are proven de-
energized. A unique and situation information tag shall be attched to
the lock and machine energizing control. This lock provision shall
not be required where the worker by his immediate proximity to the
electrical control switch (within reach) prevent inadvertent switch
on by others.
-All other fluids energy sources which can produce movements of
machine memebers shall be locked off. Pressurized fluids (air or
liquid) shall be closed off from the machine through the use of
shutoff valves, and the supply lines toward the machine reduced in
pressure to atmospheric or the machine blocked against possible
movement. All pressure-fluid accumulator and air surge tanks within
the machine shall be reduced to atmospheric pressure or the machine
blocked against possible movement.
-All mechanical gravity fall potential energy within the machine shall
be reduced to zero, or as nearly so as possible, by lowering elevated
machine parts to the floor, solid surfaces or by cribbing and
blocking them to prevent the machine parts from falling.
-All mechanical/kinetic rotating machine energy within the machine
shall be reduced to zero, or as nearly so as possible, by slowing the
rotating parts to stop.  In the alternate the worker shall be guarded
from the rotating parts of installing temporary guards. Loose machine
parts including machine parts, arms knives, etc. shall be locked or
secured to prevent possible injury to workers.
-Necessary work on the machine shall be performed. Upon completion,
all guards, tie off, valves, cribbing and blockages shall be removed
the machine in a manner to prevent worker injuries.  The machine
shall be re-energized and run experimentally. The fully functional
machine shall be formally returned to service and the operations
manager shall countersign the safety machine out tag, and the work
order.
-The employer shall formally document his safe machine maintenance
program.  He shall develop a training program to instruct affected
maintenance and operations workers and management.
-The employer shall train his workers in the safe machine maintenance
program. The training shall be repeated as frequently as is necessary
to maintain management and worker proficiency and compliance with the
procedures.

Issued

Apr 4, 1989

Abate by

Apr 24, 1989

Penalty

Initial $300 · Current $210 Reduced

Issued

Apr 4, 1989

Abate by

Apr 24, 1989

Penalty

Initial $500