OSHA Inspection: SEARS LOGISTIC SERVICES INC

Issued

Mar 10, 1995

Abate by

Jul 31, 1996

Penalty

Initial $5,000 · Current $2,500 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 are free from recognized hazards that were
causing or likely to cause death or serious physical harm to
employees in that workers were required or permitted to lift
packages which were in excess of the calculated maximum
permissible lift, or between the acceptable limit and the Maximum
Permissible Lift, resulting in stresses that had caused, were
causing, or were likely to cause musculoskeletal injuries.
a) Loading dock area: Two employees were required to lift
Sauder Entertainment Centers weighing 232 pounds each, from
the forks of a lift truck to a pallet resting on the floor.
The evaluation of this manual lifting task, which is in
excess of the calculated maximum permissible lift, indicated
that employees were exposed to a hazard which is causing or
is likely to be causing musculoskeletal injuries.  The
employer did not implement an effective control strategy to
reduce or eliminate such injuries.  The injury and illness
records for 1993 and 1994 documented  musculoskeletal
injuries.
b) Loading dock area: Two employees were required to lift
Sauder Entertainment Wall Systems weighing 265 pounds each,
from the forks of a lift truck to a pallet resting on the
floor.  The evaluation of this manual lifting task, which is
in excess of the calculated maximum permissible lift,
indicated that employees were exposed to a hazard which is
causing or is likely to be causing musculoskeletal injuries.
The employer did not implement an effective control strategy
to reduce or eliminate such injuries.  The injury and
illness records for 1993 and 1994 documented
musculoskeletal injuries.
c) Loading dock area: Two employees were required to lift
Sauder Dressers weighing 135 pounds each, from the forks of
a lift truck to a pallet resting on the floor.  The
evaluation of this manual lifting task indicated that
employees were exposed to a hazard which is causing or is
likely to be causing musculoskeletal injuries.  The lift
falls between the acceptable limit and the Maximum
Permissible Lift, and employer did not implement an
effective control strategy to reduce or eliminate such
injuries.  The injury and illness records for 1993 and 1994
documented  musculoskeletal injuries.
d) Loading dock area: Two employees were required to lift
Sauder Double Desks weighing 135 pounds each, from the forks
of a lift truck to a pallet resting on the floor.  The
evaluation of this manual lifting task indicated that
employees were exposed to a hazard which is causing or is
likely to be causing musculoskeletal injuries.  The lift
falls between the acceptable limit and the Maximum
Permissible Lift, and employer did not implement aneffective control
strategy to reduce or eliminate such
injuries.  The injury and illness records for 1993 and 1994
documented  musculoskeletal injuries.
e) Loading dock area: Two employees were required to lift
Sauder Armoires weighing 117 pounds each, from the forks of
a lift truck to a pallet resting on the floor.  The
evaluation of this manual lifting task indicated that
employees were exposed to a hazard which is causing or is
likely to be causing musculoskeletal injuries.  The lift
falls between the acceptable limit and the Maximum
Permissible Lift, and employer did not implement an
effective control strategy to reduce or eliminate such
injuries.  The injury and illness records for 1993 and 1994
documented  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 in the workplace.  This analysis should include
development and use of an ergonomic checklist and employee
questionnaire.  Periodic surveys of the worksite 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 recognition,
evaluation, treatment and referral of lifting 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 lifting
injuries.  A supervisor's training program should also be
implemented to allow recognition of manual lifting hazards, and
to reinforce the employer's ergonomic program.
(4) Hazard prevention and control which includes engineering,
work practices and administrative controls:
(a) Administrative controls are implemented which reduce the
duration, frequency, and severity of 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 to this workplace
include:
(i) Set a limit on weight of individual lifts to be lifted by one
employee; (ii) Splitting of heavy double cases prior to transfer;
(iii) Train workers to slide objects from one level to the same
level by more extensive use of lift trucks at the points of
origination and destination of the loads  (iv) Limit height
(maximum and minimum) of palletized goods to be stacked manually;
(v) Place heavy items on floor with enough clearance so that
pallets can be accessed from all sides.
(c) Engineering controls are designed by a qualified 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 in this workplace
include:
(i) Use lift table and vacuum assist devices where possible; (ii)
Use scissor jacks for heaviest items to be selected (iii) Make
more extensive use of the lift trucks in place of manual
handling.
ABATEMENT SCHEDULE
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), above.
STEP 1 - 04/12/95
STEP 2 - 05/12/95
STEP 3 - 06/11/95

Issued

Mar 10, 1995

Abate by

Sep 15, 1995

Penalty

Initial $7,000 · Current $5,000 Reduced

Issued

Mar 10, 1995

Abate by

Mar 18, 1995

Penalty

Initial $2,500 · Current $1,250 Reduced

Issued

Mar 10, 1995

Abate by

Aug 1, 1995

Penalty

Initial $2,500 · Current $1,250 Reduced

Issued

Mar 10, 1995

Abate by

Aug 1, 1995

Penalty

Initial $2,500 · Current $1,250 Reduced

Issued

Mar 3, 1995

Abate by

Mar 13, 1995

Issued

Mar 3, 1995

Abate by

Mar 16, 1995

Issued

Mar 3, 1995

Abate by

Mar 16, 1995

Penalty

Initial $1,000 · Current $500 Reduced