VINELAND, NJ —
OSHA Inspection: KIMBLE GLASS CO. INC.
Complaint inspection · Safety discipline
At a glance
On , OSHA opened a complaint safety inspection of KIMBLE GLASS CO. INC. in 537 CRYSTAL AVENUE, VINELAND, NJ 08360 (NAICS 000000). OSHA activity number 17782871.
OSHA opens inspections for many reasons — routine scheduling under a national or local emphasis program, an employee complaint or referral, or a follow-up after a reported injury. Opening or conducting an inspection is not itself an allegation or a finding that this employer broke any rule; any findings appear as the citations listed below, and citations can be contested, reduced, or withdrawn.
Where did this inspection happen?
- Establishment
- KIMBLE GLASS CO. INC.
- Site address
- 537 CRYSTAL AVENUE
- City
- VINELAND
- State
- NJ
- ZIP
- 08360
What kind of inspection was it?
- Inspection type
- Complaint (B)
- Scope
- Partial (B)
- Discipline
- Safety
- Advance notice
- No
- Union status
- Y
When did the case open and close?
- Opened
- Closing conference
- Case closed
- Data loaded
Establishment context
- NAICS code
- 000000
- SIC code (legacy)
- 3229
- Employees
- 1300
- Ownership type
- A
- Industry flags
- Manufacturing safety.
Citations
2 citations on file for this inspection.
1904.2 A
- Issued
- Oct 8, 1991
- Abate by
- Jan 7, 1992
- Penalty
- Initial $6,300 · Current $2,925 Reduced
Recent events (2)
- — I (W) $2925.00
- — Z (W) $6300.00
5(a)(1)
- Issued
- Oct 7, 1991
- Abate by
- Oct 11, 1992
- Penalty
- Initial $4,500 · Current $4,095 Reduced
General-duty citation text
rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The foot rest. %% 4) develop and use a machine vision inspection system. Use a vacuum picking system to extract the tubes when necessary. The handpiece must not present additional cumulative trauma disorder (CTD) hazard. %% g) Units Department - KU-3 - On or about 6/13/91, Employees were exposed to the following hazards; %% employer did not furnish employment and a place of employment which 1a) Awkward Postures/Frequent repetitions - The worker's hands show ulnar deviation and abduction of the elbows while manipulating the tubes. Ulnar deviation is associated with the development of carpal tunnel syndrome while the insertion of the hands into a box with elbow abduction has been associated with other UECTD. The combination of frequency and poor wrist and arm posture and some force is associated with the development of carpal tunnel syndrome. %% b) The reach to the conveyor is greater than the recommended were free from recognized hazards that were causing or likely to cause 18 to 20 inches. This is true of both the supply conveyor and the one that the employee puts full boxes on. Such reaches are associated with the development of UECTD. %% 2) Forceful Exertions - The exertions displayed by the employees are moderate and are important as contributors to the development of CTS and other UECTD. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient death or serious physical harm to employees in that employees were support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% exposed to: 1a) Develop a tool to collect the tubes which can be %% a) Mercury Calibration of Laboratory glassware - On or about 5/10/91, employees were exposed to the hazards of: 1) Frequent Repetition - This job requires repeated finger and hand manipulations and if the work manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% b) Reposition the conveyors so the employee does not have to reach more than the recommended 20", nor higher than the shoulder. %% 2) See #1 above for recommended control. %% pace is maintained throughout the day it would 3) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly present a hazard for the development of Upper designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. Extremity Cumulative Trauma Disorders (UECTD's) such as %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% h) Units department - KU2 Bagger - on or about 6/10/91, Employees were exposed to the following hazards: %% 1a) Awkward postures/Frequent repetitions - The employee Carpal Tunnel Syndrome (CTS). bends at the waist to put boxes in the bottom of a gurney. This action may be responsible for the development of back pain and injury even though the weight of apparently small. when the employee bends at the waist, the weight of the upper body is added to the weight causing stress on the back especially at the L5-S1 joint. As with any repetitive task, there is potential for the development of UECDT. %% b) The employee uses a one handed pinch grip to retrieve empty boxes to the loading area. Pinch grips with force are associated %% with the development of CTD. 2) Awkward postures a) The task is performed with the work at eye level to bench height requiring the employees to move their heads up and down to see the work. The seating used for the task %% 2) Work Place conditions - Long periods of standing on hard surfaces are associated with leg pain and static loading and other fatigue factors which can lead to cumulative trauma disorders. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to those listed above. %% is inadequate for proper support during this Some feasible and acceptable abatement methods among others, to correct these hazards are: %% 1a) Implement and use job rotation and adequate rest breaks to limit the exposure of the employee to like muscle group activities. %% Provide spring loaded gurneys which will lower as the weight is added so that the employee need not bend. %% b) Train the employee in the essentials of body mechanics and activity. This posture is consistent with the the necessity to use two handed power lifts when lifting objects. %% 2) Provide anti-fatigue mats and provide for regular breaks where the employee may sit, lay down, or perform some stress-relieving exercises. %% i) Units department - Carton/Box Assembly adjacent to KU-2. On or about 6/10/91, employees were exposed to the hazards of: %% 1) Awkward postures/Frequent Repetitions - The employee development of neck and back pain. assembles a box on a table which is very low to the ground. Bending over at the waist to perform hand intensive actions is associated with the development of back pain and also shoulder pain. The employees are forming between 1 and 2 boxes per minute. Combined with force and posture, there is potential to develop CTD. %% 2) Forceful exertions: Box assembly is associated with high hand forces which are in turn important in the development of carpal tunnel syndrome. b) There is some wrist extension when marking %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable methods, among others, to correct these hazards are; %% 1) Provide for employee rotation and adequate reset breaks from activities using the same muscle groups. %% the glassware. Frequent wrist stress in awkward Provide adequate work space at the appropriate height of the posture is associated with the development of carpal tunnel syndrome. 3) Workplace conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. other, taller table. This sort of work must be done at a height that the employee need not lift the elbows above the shoulder nor bend at the waist. %% 2) See #1 above for recommended controls. %% j) Units department - "B: Line" - On or about 6/13/91, employees were exposed to the hazards of: %% Insufficient support due to inadequate backrests can 1) Awkward postures/Frequent repetitions: The workers hands show many fine movements with the left and right wrists. Such movements are associated with the development of CTD. The combination of frequency and poor wrist posture and some force is associated with the development of carpal tunnel syndrome. %% 2) Forceful exertions: The exertions displayed by the employees in this segment are moderate and are important contributors to the development of CTD. cause undue stress on the muscles and vertebrae of %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% the back which is consistent with the development of The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) Develop a tool with a larger handle to collect the tubes with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% back pain and injury. Many of the employees have to sit A machine vision/video method of inspection would eliminate the need to perform the extraction using the tool. This should be investigated. %% 2) See recommendation #1 above. %% 3) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 up in their chairs because there is insufficient inches provided horizontally at the knee and the ankle adjustment in seat height or in the work surface. 4) Tools and clothing - Table surface edges are sharp at positions where the employees rest their forearms while performing their jobs. Resting of the forearms on sharp surfaces is consistent with the development of respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the tendonitis and restrictions of blood flow. muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the %% foot rest. %% k) Units department - "F" Line - On or about 6/13/91, employees were exposed to the hazards of: %% 1) Awkward posture /Frequent repetitions: The worker demonstrates ulnar deviation while picking up the bundle of pipettes. Frequent finger motions and hand motions are associated with the development of CTD. The combination of frequency and poor wrist postures and some force is associated with the development of The exposure to these hazards could lead to cumulative carpal tunnel syndrome. Frequent and severe ulnar deviation is associated with the development of carpal tunnel syndrome. %% 2) Forceful exertions: The exertions displayed by the employees in this segment are moderate and are important as contributors to the development of CTD. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support trauma disorders such as, but not limited to, those due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, listed above. to correct these hazards are: %% Some feasible and acceptable methods, among others, to correct these hazards are: %% %% 1) Develop a tool with a larger handle to collect the pipettes which can then be manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% A machine vision/video method of inspection would eliminate the need to perform the extraction using the tool. This should be investigated. %% 2) See recommendation in #1 above. %% 3) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% Provide anti-fatigue mats for standing employees. %% l) KU Dept. - Line 23 - On or about 6/13/91, employees were exposed to the following hazards: %% 1) Frequent repetitions: Employees use a series of very fine hand and finger movements to pick up the vials. The worker(s) handle in excess of 100 units per minute. High frequency of fine finger motion coupled with force is associated with the development of carpal tunnel syndrome. %% 2) Forceful exertion/clothing: The force used here is not excessive but in concert with the frequency may be associated with an increased rate of CTD. The use of gloves decreases the sensitivity of the fingers causing the employees to grasp harder than with bare hands. The increased force may be associated with the development of carpal tunnel syndrome. %% 3) Work place conditions: standing for long periods of time is associated with static pooling, back pain, and other circulatory problems. %% The exposure the these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable methods, among others, to correct these hazards are: %% 1) Investigate the potential to automate this station. Institute employee rotation and adequate rest breaks as previously described. %% 2) Investigate the use of gloves with a high coefficient of friction so that the force needed to do the tasks in this plant are made minimum. %% 3) Provide anti-fatigue mats and adequate rest breaks where employee can sit, lay, or exercise as appropriate. %% m) KV Dept. - Bagger for lines 22 and/or 23. On or about 6/13/91 employees were exposed to the hazards of: %% 1) Frequent Repetitions: Frequent repetitions were observed to be high for all the operations on this line. High frequency of motion in the hands is associated with the development of carpal tunnel syndrome. %% 2) Awkward postures: The worker's hand shows ulnar deviation and abduction of the elbows while manipulating the tubes. Ulnar deviation is associated with the development of carpal tunnel syndrome while the insertion of the hands into a box with elbow abduction has been associated with other UECTD. %% 3) Forceful Exertions: The force used in these motions are moderate and should be considered to be related with posture and frequency to the development of CTD. %% It was observed that some employees turned the caps on the bottles to make sure they were tight. The rotary motion with the apparent force is related to the development of CTD. %% 4) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) Implement employee rotation to tasks which do not use the same muscle groups. %% 2) Develop a tool to collect the vials which can be manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% Reposition the conveyors so that the employee does not have to reach more than the recommended 20", nor higher than the shoulder. %% 3) Adjust the torque on the capping machine so that the employee need not hand tighten the caps. %% 4) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% n) KV Dept. - Onion Sin Ware - On or about 6/14/91, Employees were exposed to the following hazards: %% 1) Awkward Positions/ Frequent Repetitions: Employees were observed to hold boxes of ware on a hand with the wrist fully extended while turning the box. This causes a great force in the wrist which is associated with the development of CTD. The frequency was moderate and could be considered to be associated with the development of CTD. %% 2) Forceful exertion: The tool the employees use to extract defective ware has a small handle. the use of small handles increases the force necessary to hold the tool and manipulate it. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) Develop vacuum operated tools for the culling operation as described in operations above. %% Investigate the use of machine vision for quality control and instruct the employees in the basics of biomechanics and in the importance of maintaining neutral positions for the wrist. %% 2) Make the handle larger and more ergonomically designed. %% 3) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% o) K V Dept. - Fletcher Terry Cutter(s) - On or about 6/14/91 Employees were exposed to the hazards of: %% 1) Awkward Posture - The employee bends at the waist to retrieve glassware from a box on the floor. This is associated with back injury and pain. %% Exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to , those described above. %% Some feasible and acceptable methods, among others, to correct these hazards are: %% 1) Provide shallower boxes that can be set on a table so that the employee need not bend over to get the ware. %% p) Container pack - Warechecking - The employees are exposed to the hazards of: %% 1) Frequent repetition - The employees are exposed to constant repetitions of lifting, flipping, and shaking of cartons of ware. These types of motions are associated with the development of CTD. %% 2) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% 3) Inadequate tools - The tool the employees use to extract defective ware has a small handle. The use of small handles increases the force necessary to hold the tool and manipulate it. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, 1) Control for this task primarily involves rest breaks from the to correct these hazards are: %% 1) Employee rotation of duties: use a shaker table to settle the ware. Rotation of employees must be to positions which do not use the same muscle groups. An Ergonomist should determine what the optimum rotation schedule should be. Investigate whether or not this operation could be handled with automation. %% 2) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance manipulation at set times through the work shift. Recommended between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis break periods are five minutes every hour and an additional of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not break of 15 minutes every two hours. These break times are to reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% 3) Make the tool handle larger and more ergonomically designed. %% q) Container Pack Dept. - Shrink Wrapping - On or about 6/17/91, employees were exposed to the following hazards: %% 1) Frequency & repetitions: The employees are exposed to be a period where there is no hand or finger manipulation constant repetitions of lifting and turning boxes in connection performed. %% 2) Educate the employee on the basics of body biomechanics and the importance of maintaining good posture while seated. %% with shrink wrapping. The frequency may be a factor in the development of CTD. %% 2) Prolonged Standing: Prolonged periods of standing is associated with static pooling, leg and back pain. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to those listed above. %% Use an ergonomically designed stool to place the employee Some feasible and acceptable abatement methods, among others, to correct these hazards are; %% 1) Investigate the use of continuous feeding sealer machines for this operation. %% 2) Provide anti-fatigue mats and allow for adequate rest periods and rotation. %% r) Container Pack - Ware Flipping - On or about 6/17/91, employees in a position which does not require the employee to raise were exposed to the hazards of: %% 1) Awkward Posture - The boxes are kept on a gurney before loading and are returned to gurney level and loaded up. This requires frequent bending which is associated with the development of low back pain and shoulder pain and other UECTD. %% Exposure to these hazards could lead to cumulative trauma disorder such as, but not limited to, those described above. and lower the head to see where to make the marks. %% Some feasible and acceptable methods, among others, to correct these hazards are; %% 1) Provide weight compensating containers which will raise and lower with the weight so that the employee need not bend to retrieve the boxes. %% s) Decorating Department - Manual Sonic Sealer - On or about 6/17/91 employees were exposed to the hazards of: %% %% 1) Frequent repetitions: employees use pinch grips to feed caps into a machine. The observed frequency is high. High frequency is associated with the development of CTD. %% 2) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the Investigate the use of computer aided vision to see the development of back pain and injury. Many of the employees meniscus and robotically place the marks. %% Place the work at a level which is at or below the worker's eye level. Ideally, the work level should be below the shoulders for best ergonomic control. have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% %% 1) Investigate the automation of this task. %% Provide employee rotation and adequate rest breaks for the employee where the motions is different than that used in this operation, using different muscle groups %% 2) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the 3. A fully adjustable seat and adequate leg room should be work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting provided for each employee. In general, the clearance the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. between the top of the seat pan and the bottom of the work Training and adjustment time should also be provided for the foot rest. %% t) Decorating Department - Multipack Machine - Feeder - Employees were exposed to the hazards of: %% 1) Frequent Repetitions: The employee repeatedly grasps ware with a power grip and places it onto a conveyor. The observed frequency was sufficiently moderate to contribute to CTD. %% surface should be about 11 inches with about 24 to 32 inches 2) Awkward Positions - The supply box is horizontal requiring provided horizontally at the knee and the ankle respectively. The seat should be large ( a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the employee to reach up and into the box to retrieve ware. This type of reach is associated with the development of shoulder pain. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the the seat back. A porperly designed back rest should support development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% the spine between the L3 and L5 vertebrae. This support 1) Institute appropriate employee rotation as described previously. %% 2) Tilt the box toward the employee using a tilted platform. %% 3) A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle generally restores the lordosis of the spine and allows the respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes chair to assist in supporting the weight of the upper body rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. which provides relief for the muscles of the back. Employees %% should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat alignment. u) Decorating Dept. - Multipack Machine, Machine Operator. On or about 6/17/91, employees were exposed to the following hazards: %% 1) Awkward Posture - The boxes into which the employees put ware are set too high on the table requiring the employee to reach the high. The port at which the ware is deposited is too far away from the employee. This causes shoulder pain and UECDT. %% The exposure to these hazards could lead to cumulative trauma %% disorders such as, but not limited to those listed above. %% Some feasible and acceptable abatement methods, among others to to correct these hazards are: %% 1) Move the outer port closer to the employee and train the employee to fill the box sitting on the surface. %% An automatic bagging device would eliminate frequency of handling for the employee. If seating adjustments are such that the employees feet do not %% v) Decorating Dept. Cage 3, bagger - On or about 6/17/91, employees were exposed to the hazards of; %% 1) Awkward & Repetitive Motion: There are a number of fine hand motions used to put ware in bags and twist tie them which can be related to the development of CTD. %% Exposure to these hazards could lead to cumulative trauma disorders such as but not limited to, those listed above. reach the ground an adjustable foot rest should be provided. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) Consider automated heat shrink packaging for this. %% w) K V and Decorating Depts - Lines 81,21,19, and Cage 3 - On or about 6/14/91, employees were exposed to the hazards of: %% Training and adjustment time should be provided for the 1) Frequent Repetition; The employee repeatedly reaches with a hand in a fully pronated position to catch tubes travelling on a mesh conveyor. A pulper pinch grip is used to bring ware to the box where it is loaded into boxes. There is a moderately high frequency rate for this job. This frequency with poor wrist posture is associated with the development of CTD. %% 2) Awkward Posture - When the employee reaches behind her to collect tubes from the line it presents several foot rest. hazards. The wrist shows radial deviation and extreme %% 4. Round off or pad the edges where the employee's forearms might come in contact with the work surface. Use non-absorbent material so that the padding does not become a mercury vapor hazard. extension. Combined with the pinch grip used to grasp the tubes, this presents a condition which is a recognized stressor for CTD. The reaching behind is a stressor related to the development of thoracic outlet syndrome. %% 3) Forceful Exertions - The employee must use greater force when grasping the tubes when they are grasped from behind than when they are retrieved from the line. %% 4) Workplace conditions - The seating provided for the employee is inadequate. See previous comments for seating. %% Exposure to these hazards could lead to cumulative trauma disorders, such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are; %% 1) Slow the lines. %% 2) Slow the lines and train the employees not to reach behind to grasp the tubes. Train the employees in the basics of biomechanics so that they can understand why they must maintain neutral body positions. Enforce requirements that employees do not perform injurious actions. %% Provide adequate rest breaks where no similar hand/wrist actions are performed. %% 3) See recommendations for #2 above. %% 4) See previous comments for seating. %% ABATEMENT SCHEDULE %% STEP #1: Effective administrative protection, such as employee training, physical assessment, job rotation, etc. shall be provided as an interim protective measure until feasible engineering or permanent administrative controls can be implemented which will reduce employee exposure to nominal risk. %% STEP #2: Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposure to hazardous conditions as referenced in this citation. This plan shall include, at a minimum target dates for the following actions which must be consistent with the abatement dates required by this citation: %% A) Evaluation of engineering/administrative control options: B) Selection of optimum control methods and completion of design: C) Testing and acceptance or modification/redesign of controls %% All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person. Thirty (30) day progress reports are required during the abatement period. %% STEP #3 Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance. %% In addition to the engineering and administrative controls listed above, consideration should be given to the establishment of an ergonomic program such as follows: %% A. Engineering and Administrative Controls: Cumulative trauma disorder hazards can be controlled through proper engineering design of the job, work station, and equipment so that the work can be performed independent of specific worker characteristics and techniques. This requires that the job be made to fit the worker and not make the worker fit the job. %% Engineering controls deal with job, task, or equipment modification to reduce extreme postures, excessive forces, and repetitive motions. To be effective employee input is necessary since improperly designed work stations and controls will not be used if employees believe they interfere with their work. Also, after installation, the effectiveness of the controls must be evaluated and modified if necessary to insure their effectiveness. %% Administrative controls include (1) training of new employees in safe work techniques including lifting, working with minimum strain on the body, and minimizing the application of forces with the fingers; (2) job rotation and job enhancement; (3) adequate mandatory rest breaks and (4) implementation of an exercise program. %% B. Consultant Assistance A properly trained ergonomic consultant should be hired to assist in training employees and implementing the recommendations made. The consultant should review OSHA recommendations, perform a systematic evaluation with regard to existing and new work practices and work station design for all plant operations to determine CTD hazards, recommend engineering and administrative controls to reduce or eliminate ergonomic stressors, assist in implementing the recommendations, evaluate the effectiveness of the controls implemented, and make the recommendations if necessary. %% C. Medical Management Program A medical management program is necessary to monitor employees and prevent early symptoms from progressing to injuries or illnesses. This program should include: determining the extent of injuries and illnesses; determining if injuries and illnesses are caused or aggravated by work; educating all employees and supervisors on early signs of injuries and disorders and encourage early reporting; instituting a formal documented tracking and surveillance program to monitor injury trends in the plant; providing adequate treatment of ergonomic related cases (including not reassigning employees to a job until it has been modified to minimize the hazards that result in the injury); and, after surgery or other aggressive intervention, allow adequate time off for recovery. %% Preventive measures that should be instituted include early physical evaluation of employees with CTD symptoms; allowing adequate time off after a CTD is diagnosed; and provided utilization of physical therapists to develop and implement conservative treatment measures upon detection of CTD symptom. %% D. Training Program %% A training program is necessary to alert employees in the hazards of CTDs and controls and work practices that can be used to minimize the hazards. This includes designing and implementing a written, training program for managers, supervisors, engineers, union representatives, health professionals. and employees on the nature, range, causes, and means of prevention of ergonomic related disorders. The training program for new and reassigned workers should allow demonstrations of safe and effective methods of performing their job; familiarize employees with applicable safety procedures and equipment; allow the new or reassigned employee to work with a skilled employee and/or provide on the job training for specific jobs; and allow new or reassigned employees to condition their muscle/tendon groups prior to working at full capacity which has been determined to be safe and cause no ill effects. %% Workers should be instructed in the basics of body biomechanics to minimize ergonomic hazards associated with their jobs. This should include, but not be limited to, the items noted below: %% Avoid postures where: the elbow is above mid torso the hand is above the shoulder the arms must reach behind the torso %% Avoid wrist postures where there is: inward or outward rotation with bent wrist excessive palmar flexion or extension ulnar or radial deviation pinching or high finger forces with above postures %% Avoid mechanical stress concentrations on elbows, palms, and backs of fingers. %% General lifting guidelines: keep the load close to the body use the most comfortable posture lift slowly and evenly (don't jerk) do not twist the load securely grip the load use a lifting aid or get help %% Prolonged standing often puts stress on the spine and back muscles, causing severe pain and even permanent damage to the body tissue. in general, maintaining any set muscles in a rigid, unsupported position for long periods of time will result in muscular fatigue and strain. %% If work must be done standing, the following guidelines are recommended %% 1. There must be sufficient foot and knee room for mobility 2. The worker should not have to adopt a bent posture 3. The working height should be such as to allow the use of the arm muscles to the best mechanical advantage. 4. Object handling height should be at or just below elbow height. %% Standing-sitting work stations are more beneficial to the circulatory system as it results in: (1) better posture, (2) decreased muscle fatigue, (3) reduced static pooling, and (4) reduced back pain. %% b) K V Dept. - KV66/11 machine Operators - On or about 5/16/91, employees were exposed to the hazards of: %% 1) Awkward Postures - a) The employee bends at the waist to retrieve glass tubes from the bin on the floor. The height of the bin precludes the employee from bending his knees while lifting. This posture greatly increases the bending moment of the spine which in turn greatly magnifies the force on the L5-S1 joint. Also, this posture greatly increases the risk of muscular based back pain due to stress. %% b) The employee who loads the stock into the KV machines must reach up and away from his body with multiple tubes in his right hand to load the machine. The bending causes an increase in the force at the L5-S1 joint can be a cause for back pain and injury. The lifting away form the body and above the shoulder may be responsible for other UECTD such as shoulder pain and neck pain. %% 2. Forceful exertions - The employee grasps as many tubes as he can from the bin on the floor to stock the bin near the KV machine. He uses a full arm clamping force to grasp the glass. This force is associated with shoulder pain and other UECTD. %% 3. Working conditions - The employees are required to work in a hot environment. Heat presents an ergonomic stressor in that it increases the rate of fatigue for all the operations. Fatigue is associated in the development of UECTD. %% 4. Tools and Clothing An employee was observed to be wearing shorts. Shorts do not provide protection from either heat, nor light radiation from the machines. This may be a skin cancer hazard. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1a) Use smaller boxes to hold the stock and put the boxes on a table so that the employee need not bend to retrieve the stock. The employee should not have to lift from lower than approximately his waist level nor above his shoulders. %% b) Provide a heat shield between the step stair already present and the KV machine so that the employee can get closer to his work. %% Provide that the step stair be high enough that the employee can reach straight across to insert the tubes without lifting up from his shoulders. %% 2) Train the employee to take smaller loads, to limit the number of glass rods to that which can be comfortable carried using a two handed power grip rather than the maximum amount of weight he can carry without dropping the product. %% 3) Where possible, use engineering controls to decrease the temperature. %% Institute a heat stress monitoring program and rotate employees accordingly, providing adequate breaks from the hot environment. %% 4) Institute and enforce a policy of appropriate wearing apparel on this work floor. %% c) K V Dept - Towel Bar machine - On or about 5/16/91, Employees were exposed to the following hazards: %% 1) Frequency: The employee repeatedly bends two ends of a glass bar. Each unit requires supination of the hand while holding the rod, and a series of pinch grips to manipulate the rods. Thousands of units are produced each day. This combined with the temperature and use of thick gloves may be associated with increased risk of carpal tunnel syndrome. %% 2) Awkward Postures: The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in work surface. %% 3) Forceful Exertions: The use of thick gloves decreases the tactile feedback used to limit the amount of force generated by the fingers. The use of such gloves increases the force generated by the employee. Excessive force is associated with the development of carpal tunnel syndrome. %% 4) Workplace conditions: The employees are required to work in a hot environment. Heat presents an ergonomic stressor in that it increases the rate of fatigue for all the operations. Fatigue is associated in the development of UECTD. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) Provide automation of this operation. Provide adequate rest periods for this operation determined by an ergonomist. %% 2) A fully adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should be provided. Training and adjustment time should also be provided for the foot rest. %% 3) Automate this operation. because of the necessity of using heat resistant gloves in this operation and the reported failure of the gear to prevent this injury, the best remediation of this operation is to investigate automation of the task. %% 4) Where possible, use engineering controls to decrease the temperature. %% Institute a heat stress monitoring program and rotate employees accordingly, providing adequate breaks from the hot environment. %% d) Units Department - KU2 - On or about 6/10/91, employees were exposed to the following hazards: %% 1) Awkward Postures/Frequent repetitions: %% a) The worker's hands show ulnar deviation and abduction of the elbows while manipulating the tubes. Ulnar deviation is associated with the development of carpal tunnel syndrome while the insertion of the hands into a box with elbow abduction has been associated with other UECTD. %% The combination of frequency and poor wrist posture and some force is associated with the development of carpal tunnel syndrome. %% b) The reach to the conveyor is greater than the recommended 18 to 20 inches. This is true of both the supply conveyor and the one that the employee puts full boxes on. Such reaches are associated with the development of UECTD. %% 2) Forceful exertions: The exertions displayed by the employees in this segment are moderate and are important as contributors as previously described. %% 3) workplace conditions: The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back, pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1a) develop a tool to collect the tubes which can be manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% b) Reposition the conveyors so the employee does not have to reach more than the recommended 20", nor higher than the shoulder. %% 2) See #1 above for recommended control. %% 3) A fully adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be 11 inches with about 24 to 32 inches provided horizontally at the knee and ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% e) Units department - Line "E" - On or about 6/10/91, employees were exposed to the hazards of: %% 1) Awkward Posture/ Frequent repetitions - The worker's hands show ulnar deviation and abduction of the elbows while manipulating the tubes. Ulnar deviation is associated with the development of carpal tunnel syndrome while the insertion of the hands into a box with elbow abduction has been associated with other UECTD. The combination of frequency, poor wrist posture, and some force is associated with the development of carpal tunnel syndrome. %% 2) Forceful Exertions - The exertions displayed by the employees are moderate and are important as contributors to the development of CTS and UECTD. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable abatement methods, among others, to correct these hazards are: %% 1) develop a tool to collect tubes which can be manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% 2) A machine vision/video method of inspection would eliminate the need to perform the turning over motion showing gross ulnar deviation. This should be investigated. %% 3) A fully adjustable seat and adequate leg room should be provided for each employee. In general, the leg clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes rapidly without the need for special tools or knowledge. There should be hands-on training given to all employees in the proper adjustment and use of their seating. Time should be allotted at the beginning of each shift for the proper seat adjustment. %% If seating adjustments are such that the employees feet do not reach the ground an adjustable foot rest should also be provided. Training and adjustment time should also be provided for the foot rest. %% f) Units department - 83 Line - On or about 6/1/91, employees were exposed to: %% 1) Awkward Posture/Frequent repetitions: The worker's hand shows many fine movements with the left wrist quickly extending as a tube is placed in it. The right hand must grasp a wire wound tool used to extract the tubes. This repeated motion is associated with the development of carpal tunnel syndrome. The combination of frequency and poor wrist posture and some force is associated with the development of carpal tunnel syndrome. %% 2) Forceful Exertions - The exertions displayed by the employees in this segment are moderate and are important as contributors to the development of CTS and other UECTD. %% 3) Workplace Conditions - The seating and work tables offer very little adjustment. The seating offers insufficient support for the employee's lower back. Insufficient support due to inadequate backrests can cause undue stress on the muscles and vertebrae of the back which is consistent with the development of back pain and injury. Many of the employees have to sit up in their seats because there is insufficient adjustment in seat height or in the work surface. %% 4) Tools and clothing - Some employees use forceps to extract tubes from the box. The thumb is used to close the forceps. This sort of thumb action is associated with the development of deQuervain's disease and carpal tunnel syndrome. %% The exposure to these hazards could lead to cumulative trauma disorders such as, but not limited to, those listed above. %% Some feasible and acceptable methods, among others, to correct these hazards are: %% 1. Develop a tool to collect the tubes which can be manipulated with the hand and wrist in neutral position and dumped into the box with a minimum of wrist movement. %% 2. A machine vision/video method of inspection would eliminate the need to perform the extraction using the tool. This should be investigated. %% 3. A full adjustable seat and adequate leg room should be provided for each employee. In general, the clearance between the top of the seat pan and the bottom of the work surface should be about 11 inches with about 24 to 32 inches provided horizontally at the knee and the ankle respectively. The seat should be large (a minimum of 18.2 inches wide) and fully padded. It should be covered with a porous, roughly textured moisture absorbing material. The seat pan height and depth should be adjustable as well as the angle and height of the seat back. A properly designed back rest should support the spine between the L3 and L5 vertebrae. This support generally restores the lordosis of the spine and allows the chair to assist in supporting the weight of the upper body, which provides relief for the muscles of the back. Employees should be able to make changes
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