OSHA Inspection: HUDSON COUNTY NEWS CO., INC.

Issued

1997-06-13 00:00:00

Abate by

1997-07-10 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employmnent 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 crushing hazard when working at locations on the
conveyor system where
emergency stop devices were not provided.
Full Load Back Room:  Emergency pull cords had been removed from the
conveyor system and
replaced with an on/off toggle switch.
Among other methods, one feasible and acceptable method to correct this
hazard is the
installation of emergency pull cords along the length of the conveyor
where employees would
be working.
Reference:  National Standard Safety Standard for Conveyors and related
equipment.  ANSI
B20.1-1976, Section 5.12.7,, 5.12.8, 6.01.2.2
Violation observed on or about 12/16/96

Issued

1997-06-13 00:00:00

Abate by

1998-04-01 00:00:00

Penalty

Initial $4000.00 · Current $2400.00 Reduced

General-duty citation text

which are to
be loaded into trucks for shipment.  The boxes come to the loading dock
via conveyor and are
loaded directly into some of the trucks using a telescoping conveyor which
extends into the box
of the truck.  Employees remove the boxes of the magazines from the
conveyor and place them
into trucks two stacks deep across the width of the truck.  Boxes are
stacked from the floor to
Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
about 4 or 5 tiers high.  Under certain circumstances boxes sometimes are
unloaded from the
conveyor onto a wheeled cart.  While engaged in Task 2 employees were
exposed to:
(a)  Recognized hazard of repeated, extended reaches, with a load in the
hand, to place boxes
of magazines on the back row of stacked product.  The boxes are stacked
two deep and the
employee must reach in excess of 20 inches, across the front row to place
boxes on the back
employer did not
row.  Many of the boxes can be tossed into position which minimizes the
amount of weight
which is supported with the arm extended posture, but some boxes in each
tier
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 required to perform lifting tasks and other tasks involving ergonomic
risk factors
(including but not limited to repetitive motions, high force exertions,
and awkward
must be precisely
placed which requires the use of an extended reach while supporting a load
in the hand.
Frequent reaches present a hazard as shoulder deviations create muscle and
tendon tension that
fatigues the muscles and restricts blood flow to the tissues.  Workers
were routinely exposed to
this hazard for 2 or more hours continuously or 4 or more hours in a
workshift.  Prolonged
exposure to awkward shoulder postures contributes to cell damage in the
muscle and tendon
fibers.  Fully extending the arm is consistent with fatigue rates which
are approximately 2 to 3
times faster than when the arm is in close to the body.  Frequent reaches
increase the risk of
development of acute shoulder, upper arm, and upper back muscle and tendon
fatigue and injury
such as strains, sprains, and tears.  In addition to acute muscle and
tendon fatigue and failure
there can be chronic tendon wear and tear, inflammation, and thickening
from repeated motion.
This increases the risk of developing MSDs such as bursitis, tendinitis,
and rotator cuff injuries.
(b)  Recognized hazard of prolonged torso flexion, usually with twisting,
with the arms
extended in front of the body to place product in locations below knee
level or to areas that areon the back row.  Placement to areas that are
below knee level and on the back row are
especially stressful as the load must be a considerable distance from the
body to reach the
required horizontal distance while the torso is bent forward deeply to
reach the required
horizontal distance while the torso is bent forward deeply to reach the
required vertical distance.
Prolonged torso flexion increases risk of development of low back injuries
such as muscle strain
and disk herniation.  Holding a load or twisting while flexing the torso
significantly increases
low back stress and injury.  Measurements taken show employees flex the
torso about 25 to
50 degrees and twist the torso 20 to 45 degrees to place loads to the back
row.  Employees
must flex the torso forward to about 90 degrees to place loads down onto
the first two tiers
particularly too placement on the back row.  Many of these items are
heavy,
weighing up
to 50 pounds, which creates significant compressive forces on the low back
under ideal
conditions.  Performing deep bending motions moves the load away from the
torso and due
to leveraging, the compressive force on the low back is significantly
increased.  Increasing
the flexion of the torso increases the compressive forces on the low back
as the load center
is moved away from the spine.  Frequent torso flexion increases the risk
of development of
low back injuries such as muscle strain and herniation.  Twisting the
torso during lifting
operations increases the risk of development of low back injury
significantly as it creates
non-symmetrical stress on the musculoskeletal system requiring smaller
groups of muscles
to exert force across a less structurally sound anatomical support system.
(c)  Recognized hazard of repetitive lifting, where the parameters of the
lift such as weight,
position, or frequency combine to produce an unsafe situation as defined
by NIOSH in their
"Work Practices Guide for Manual Lifting" (1991).  Employees were required
to repetitively
lift boxes weighing from 10 to 60 pounds, which exceeded the weight
recommended by
NIOSH, using the above equation.  The Cumulative Lifting Index (CLI) and
the Lifting
Index (LI) were calculated for truck loading composite lifts and for a
truck loading single
lift.  The CLI/LI were found to be 9.7 and 4, for truck loading composite
lifts, and 5 for
truck loading single lift.  CLIs or LIs of 3 or greater pose a hazard to
most employees who
perform these lifts.  Continued lifting of items in this weight range, and
with this technique,
without implementation of proper administrative and engineering controls
is consistent with
the development of low back injury.
Abatement:
1)  Develop a work station which uses lift tables or scissors jacks such
that product can be
loaded at an anatomical neutral height and then transferred to the trucks
using machinery.  Boxes
and bundles of magazines could be delivered via conveyor to a central
loading point where they
are loaded on pallets, sheets of wood, or sheets of cardboard placed on a
lift table or scissors
jack equipped with a turntable.  When the load is completed it could be
lifted from the lift table
or scissor jack using a fork lift with flat forks and a push-pull
attachment and placed directly into
the truck.  This technique would use one ergonomically designed loading
station to prepare the
loads for placement in all the delivery trucks.  Mechanical power in the
form of a fork lift would
transport and place the load eliminating lifting of individual boxes into
the truck.  Since one
forklift could service a number of loading area, this would eliminate
double handling of product
which is currently done when a cart is used for transportation. 2)  Place
a shelf in the area of the truck where the two rows of boxes are currently
stacked.
Elevating the floor of the truck by about 12 to 18 inches will allow lower
tiers of boxes to be
placed using decreased torso flexion and the upper tiers will still not
require reaches above
shoulder height.
3)  Increase the rest periods and develop rotation schemes for those
employees performing highly
repetitive lifting tasks.
4)  Limit the maximum weight of each box to no more than 40 pounds.
5)  Educate all employees and supervisors on the basics of body
biomechanics and the
importance of maintaining the body in a neutral position.
Among other methods, one feasible and acceptable abatement method to
correct this hazard
is to establish and implement an ergonomics management program which is to
establish and
implement an ergonomics management program which is monitored by a
qualified ergonomist,
and which includes a comprehensive medical management program monitored by
a health care
provider, and which consists of the following four elements:
1)  Worksite Analysis
A worksite analysis should be conducted by a qualified ergonomist to
identify existing ergonomic
risk factors in the workplace.  This analysis should include development
and use of an
ergonomic checklist and employee questionnaire.  Periodic surveys of the
workplace should be
conducted at appropriate intervals to evaluate work practices and
engineering controls.
Employee participation in the ergonomic program should be encouraged
through a mechanism
such as the ergonomic committee.
2)  Hazard Prevention and Control
Hazard prevention and control includes engineering and administrative
controls.  Engineering
controls attempt to reduce extreme postures, excessive forces and
repetitive motions.
Engineering controls designed by a properly trained ergonomic professional
to include proper
engineering design of the job, work station, and equipment so the work can
be performed
independent of specific worker characteristics and techniques.  This
requires the job be made
to fit the worker and not make the worker fit the job.
Administrative controls are implemented to reduce the duration, frequency
and severity of
exposure to hazards.  These controls may include but are not limited to:
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; job rotation
and job enhancement; and
adequate mandatory rest breaks.  Implementation of an exercise program can
also be a helpful
administrative control as it improves the overall strength and health of
the musculoskeletal
systems of the work population.
3)  Medical Management Program
A medical management program is necessary to monitor employees and prevent
early symptoms
from progressing to injuries.  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 facility; providing adequate treatment of ergonomic related
cases(including not
reassigning employees to a job until it has been modified to minimize the
hazards that resulted
in the injury); and allowing adequate time for recovery after surgery,
conservative treatment,
or work conditioning. intervention.
4)  Training Program
A training program is necessary to provide employees with understanding of
musculoskeletal
disorders, their control and proper reporting procedures so work practices
and medical
management can be developed to minimize the hazards.  This includes
designing and
implementing written training program by a properly trained ergonomic
professional for all
employees and contract personnel on the nature, causes, reporting, and
means of prevention of
ergonomic related disorders.  The training program for new and reassigned
postures) resulting in stressors that had caused, were causing or were
workers should allow
demonstrations of safe and effective methods of performing their jobs;
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
rate which has been determined to be safe and will not cause adverse
likely to cause
effects.  All employees
should be instructed in the basics of body biomechanics and work practices
to minimize the
ergonomic hazards associated with their jobs.  Re-training should be done
annually
musculoskeletal disorders, and the employer had not implemented an
effective control
strategy to reduce and/or eliminate such disorders.  The OSHA 200 Injury
and Illness logs
for the years 1994, 1995 and 1996 document the presence and severity of
work-related
musculoskeletal disorders at the facility.  Specifically:
Location:  Packing Area - Working Stations #1,2,4,5, and 7 and the Loading
or as
operations change.  Means for adequately evaluating its effectiveness
should be incorporated
ABATEMENT SCHEDULE
Step 1)  Implementation of an ergonomics program for worksite analysis,
medical management,
and training and education, as detailed in items 1-3.
Step 2)  Submit to the Area Director a written detailed plan of abatement
outlining a schedule
Dock Area
for the implementation of the engineering, administrative and work
practice controls, as detailed
in item 4, Task 1 and Task 2.
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. 90 DAY
PROGRESS REPORTS ARE REQUIRED DURING THE ABATEMENT
PERIOD.
on or about 12/19/96 and 1/15/97
Task 1: Employees select magazines from bulk shipments and place them in
boxes to fill orders.
The box being filled proceeds down a roller conveyor (take away conveyor)
and employees place
a number of magazines in each box.  Smaller quantities of magazines are
placed on a supply
shelf next to the take-away conveyor, between the take away conveyor and
the employee.  When
Step 3)  Implementation of the engineering, administrative, and work
practice controls.
these supplies of magazines are diminished they are restocked from large
quantity,
palletized
stock which is kept on the other side of the aisle from where the employee
stands.  The
employee is responsible for restocking the supply stacks during periods
when boxes are not
passing their positions.  The employee at the head of the line places
empty boxes onto the
conveyor line and places magazines into the box.  All other employees
along the line only place
magazines into the box and perform supply tasks.  While engaged in Task 1
employees were
exposed to:
(a)  Recognized hazard of prolonged torso flexion with the arms reaching
in front of the body
while moving bundles of magazines from the supply pallets to the area
adjacent to the take-away
conveyor.  The degree of torso flexion varies during the shift based on
the height of product that
is on the pallet and the size of the employee.  The employees back is
straight when dealing with
a full pallet, but bent more than 90 degrees when the pallet has been
emptied down to the last
tier.  The most stressful situation occurs when bending to transfer
bundles from the lowest levels
of the pallets.  This usually occurs later in the shift when employees are
already fatigued.  Even
when there is no load or only a light load lifted flexing the torso
creates a lifting task with the
weight of the entire upper body requiring support.  Increasing the flexion
of the torso increases
the compressive forces on the low back as the load center is moved away
from spine.  Muscle
force must continually be increased to counteract the downward force
created by the load lifted
and the weight of the upper body.  Compressive forces on the low back are
increased as muscle
force is increased, since the low back is the focal point for antagonistic
forces created by
contraction of the back muscles and downward pull of the load.  Frequent
torso flexion increases
the risk of development of injuries to the low back such as muscle strain
and disk herniation.
Holding a load while flexing the torso significantly increases low back
stress, in addition
increasing the distance the load is held from the body directly increases
the
hazard of low back
injury.
(b) Recognized hazard of repeated, extended and elevated reaches to place
stacks of magazines
into the box as it proceeds down the central conveyor.  Employees must
reach in excess of 20
inches out and away from the torso to place magazines into the box.  Job
design requires reaches
to essentially the center of the packing box to place the magazines in an
orderly manner.  The
shipping box has the flaps extended upward as it proceeds down the
conveyor.  Employees must
lift the arm 75 to 90 degrees in front of the body, to elevate the load
high enough to clear the
flaps so product can be placed in the box in an orderly orientation.
Workers were routinely
exposed to this hazard for 2 or more hours continuously or 4 or more hours
in a workshift.
Frequent reaches present a hazard as shoulder deviations create muscle and
tendon tension that
fatigues the muscles and restricts blood flow to the tissues.  Prolonged
exposure to awkward
shoulder postures contributes to cell damage in the muscle and tendon
fibers.  Fully extending
the arm is consistent with fatigue rates which are approximately 2 to 3
times faster than when
the arm is kept in close to the body.  Frequent reaches, especially when
there is a load in the
hand, increases the risk of development of acute shoulder, upper arm, and
upper back muscle
and tendon fatigue and injury such as strains, sprains, and tears.  In
addition to acute muscle and
tendon fatigue and failure there can be chronic tendon wear and tear,
inflammation, and
thickening from repeated contact between the moving and stationary
entities in the shoulder.
This increases the risk of development of MSDs such as bursitis,
tendinitis, and rotator cuff
injuries.
Abatement:
1)  Rearrange the current work station to reduce the distance and
elevation that employees must
reach to place magazines into the packing box.  The following changes will
allow the employees
to complete the picking and loading task while still maintaining less
stressful body postures.
a.  Reorient the small quantity supply shelves so they are perpendicular
to the central
take-away conveyor.  This will give the employees access to the take-away
conveyor allowing
them to place magazines into the box without reaching across items stored
between them and the
box.  Employees should be able to get close enough to place items into the
box while
maintaining the elbows in close to the torso.
b.  Create a series of openings in the small quantity supply shelving
which will give
employees direct access to the take-away conveyor.  A  cutout should be
provided about 5 to
8 feet of take-away conveyor so the packing box can be accessed while
maintaining nearly
neutral body postures.
2)  Lower the conveyor so the top of the box flap is no higher than about
elbow height.  This
modification will allow the load to be placed into the box without lifting
the arm and pulling the
elbow away from the torso.  For employees who are about 5'9" this would
involve lowering the
conveyor about 3 to 4 inches to keep the top of the box no higher than
about 47 inches.  An
alternative to lowering the conveyor would be to provide a bumper along
the length of the
conveyor to hold the outside flaps of the box down so they do not
interfere with access to the
inside of the box.
3)  Elevate the palletized supply of magazines so employees do not flex
the torso to access
bundles of magazines.  Provide lift tables which elevate the load as
weight is removed from the
pallet, thus maintaining the load at an ergonomically desirable height.
Place pallets of
magazines on top of other empty pallets so the load is elevated to
minimize torso flexion.  The
pallet should be elevated as high as possible while keeping the top of the
load no higher than
about mid-chest height.  The torso should not need to be bent forward more
than 6 to 10 degrees
from vertical to access product.
4)  Place the pallet of magazines on rotatable turntables so it can be
easily turned to provide
access while eliminating reaching across empty spaces of the pallet.
Reaches should be limited
to no more than 16 to 18 inches horizontally.
5)  Educate employees on the basics of body biomechanics and the
importance of maintaining
the body in an ergonomically neutral position.  Generally, the torso
should not be bent forward
farther than 20 degrees from vertical, reaches should be limited to
shoulder height vertically and
16 to 18 inches horizontally.  The task should be able to be performed
with the elbows in close
to the torso and the wrist should not be bent either up or down, or to
either side.
Task 2:  Truck Loading:  Employees receive filled and taped boxes of
magazines

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-31 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-10 00:00:00

Penalty

Initial $4000.00 · Current $2400.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $1200.00 · Current $720.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-09-01 00:00:00

Penalty

Initial $2000.00 · Current $1200.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-01 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-20 00:00:00

Penalty

Initial $2250.00 · Current $1350.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-02 00:00:00

Penalty

Initial $1800.00 · Current $1080.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-16 00:00:00

Penalty

Initial $1200.00 · Current $720.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $2000.00 · Current $1200.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-10 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-02 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-07-02 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-07-02 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $1600.00 · Current $960.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-03 00:00:00

Penalty

Initial $2800.00 · Current $1680.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $1600.00 · Current $960.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-27 00:00:00

Penalty

Initial $2000.00 · Current $1200.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Penalty

Initial $1600.00 · Current $960.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-07-11 00:00:00

Penalty

Initial $1600.00 · Current $960.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-20 00:00:00

Penalty

Initial $1600.00 · Current $960.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-20 00:00:00

Penalty

Initial $1200.00 · Current $720.00 Reduced

Issued

1997-06-13 00:00:00

Abate by

1997-06-25 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-19 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-19 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-07-10 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-20 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-19 00:00:00

Issued

1997-06-13 00:00:00

Abate by

1997-06-20 00:00:00