OSHA Inspection: NEW PROCESS GEAR, A DIV. OF MAGNA POWERTRAIN

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Penalty

Initial $4,500 · Current $1,688 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employment and a place of employment which were free from
recognized hazards that
were causing or likely to cause death or serious physical harm to
employees in that employees
were exposed to the hazard of being struck by the load should the overhead
hoist, below-the-
hook lifting devices or bridge crane system fail:
a)On or about 4/29/99-6/23/99, the following below-the-hook lifting
devices had
no rated load markings and no initial, frequent or periodic inspections
performed, including, but not limited to:
1.Dept. 867, AA40, two below-the-hook lifting devices attached to two
Aro overhead hoists on a bridge crane #BC930B, had no rated load
markings and no inspections were conducted.
2.Dept. 865, CC40, Dock Inspection area a below-the-hook lifting device
attached to an Aro overhead hoist on a bridge crane #BC347, had no
rated load markings and no inspections were conducted.
3.Dept. 1276, HH40, Dock Audit Area, a below-the-hook lifting device
attached to an Aro overhead hoist #822B, had no rated load markings
and no inspections were conducted.
4.Dept. 861, DD40, a below-the-hook lifting device attached to an Aro
overhead hoist on bridge crane #BC349B, had no rated load markings
and no inspections were conducted.
5.Dept. 865, BB35, a below-the-hook lifting device attached to an Aro
overhead hoist #MR331, had no rated load markings and no
inspections were conducted.
6.Dept. 864, D32, a below-the-hook lifting device attached to an Aro
overhead hoist #BC341, had no rated load markings and no
inspections were conducted.
7.Dept. 194, C30, a below-the-hook lifting device attached to an Aro
overhead hoist #BC344, next to Denison machine #10115, had no rated
load markings and no inspections were conducted.
8.Dept. 194, E28, weld booth, south side, a below-the-hook lifting device
attached to an Aro overhead hoist #893, had no rated load markings
and no inspections were conducted.
9.Dept. 560, L28, a below-the-hook lifting device attached to an Aro 1/4
ton overhead hoist #MR227, had no rated load markings and no
inspections were conducted.
10.Dept. 562, R30, a below-the-hook lifting device attached to an Aro
overhead hoist #BC517, had no rated load markings and no
inspections were conducted.
11.Dept. 580, R27, a below-the-hook lifting device at the pallet pull out
area for LaSalle 1B transfer machine, had no rated load markings and
no inspections were conducted.
12.Dept. 173, B7, a below-the-hook lifting device attached to an overhead
hoist at the Super Allcase machine, had no rated load markings and
no inspections were conducted.
13.Dept. 135, L11, a below-the-hook spreader beam lifting device
attached to an Ingersoll Rand overhead hoist #BC70 at the Broach
wash tank, had no rated load markings and no inspections were
conducted.
14.Dept. 1270, S10, Containment Area, a below-the-hook lifting device
attached to an Aro overhead hoist, had no rated load markings and
no inspections were conducted.
15.Dept. 291, J3, a below-the-hook lifting device attached to a Yale 1/2
ton overhead hoist at the Detroit Broach #290614 had no rated load
markings, the two safety hooks had broken latches and no inspections
were conducted.
Among other methods, several feasible and acceptable abatement methods to
correct
these hazards, in accordance with ASME B30.20-1993, paragraphs 20-1.2.1,
20-1.3,
and 20-1.4, are to:
1.Prior to initial use, all new, modified or repaired lifting devices
shall be
inspected by a designated person and an operational test performed to
verify
compliance.
2.Mark the rated load capacity of the lifting device on the main structure
or
equivalent.
3.Conduct frequent and periodic inspections of the lifting devices for
wear,
deterioration or malfunction in accordance with ASME B30.20.
b)On or about 4/29/99-6/23/99, the following overhead hoists had hook
safety
latches broken or missing, pendant controls were not labeled and the hoist
was used to lift in excess of the rated load, including, but not limited
to:
1.Dept. 1276, HH40, Dock Audit Area, an Aro 1/4 overhead hoist had
a broken hook safety latch.
2.Dept. 890, GG30, a Yale one ton overhead hoist, Jib #803, at U.S.
Broach #291235, had a broken hook safety latch.
3.Dept. 1460, F34, Battery Change Area, east end, a Cleveland
Tramrail overhead crane #201A, the pendant control was not labeled
as to its functions and the hoist was rated for 3000 lbs. was used to lift
batteries weighing in excess of 3000 lbs.
4.Dept. 1400, Waste Treatment Bldg, second floor, a Coffing 1/2 ton
overhead hoist had a broken hook safety latch.
5.Dept. 1453, J23, CM Cyclone overhead hoist #MR162 had a broken
hook safety latch.
6.Dept. 188, S19, Budgit overhead hoist at the Pot Broach #257864 had
a broken hook safety latch.
7.Dept. 1270, S10, Containment Area, Aro overhead hoist had a broken
hook safety latch.
Among other methods, several feasible and acceptable abatement methods to
correct
these hazards, in accordance with ASME/ANSI B30.16-1987, paragraphs
16-1.2.9,
16-2.1, 16-2.3.3(b)(7) and 16-3.1.2(h), are to:
1.Replace safety latches on the hooks.
2.Identify pendant control functions.
3.Only lift what the overhead hoist is capable of lifting.
c)On or about 4/29/99-6/23/99, the following bridge crane/jib structures
had
not been re-rated after modifications were made, and/or the supporting
structures for the hoists were underrated for what the hoist capacity was
rated for, and/or the rated load capacity for the supporting structure was
unknown, including, but not limited to:
1.Dept. 1276, HH40, the bridge crane structure #822B had extensions
welded on to the west end.  There was no written documentation of
the re-rating of the system and the tests performed confirming the
load rating of the system.
2.Dept. 861, DD40, an Aro overhead hoist rated at 1/2 ton was mounted
on a bridge crane structure #BC349B which was rated for 1/4 ton.
3.Dept. 867, BB40, two Aro overhead hoists each rated for 1/2 ton were
mounted on a Spanco bridge crane structure #BC930B rated for 1/2
ton and each bridge rail were rated for 1/4 ton each.
4.Dept. 562, S30, PCR, an Aro 1/4 ton overhead hoist was attached to
a bridge rail system without any rated load capacity markings.
5.Dept. 1270, S10, Containment Area, an Aro 1/4 ton overhead hoist
was attached to a bridge rail system without any rated load capacity
markings.
Among other methods, several feasible and acceptable abatement methods to
correct
these hazards, in accordance with ANSI B30.11-1973, paragraphs 11-1.1,
11-1.3.5,
and 11-2.2.2, are to:
1.Prior to initial use, all new extensively repaired, modified or altered
equipment shall be tested by or under the direction of an appointed person
and a written report furnished by such person confirming the load rating of
the system.
2.After modifications are made, all building and other support structures
shall
be thoroughly checked by a qualified engineer prior to retesting and
marking.
3.Prior to installation and use, ensure the supporting structure (jib,
monorail,
bridge) is designed to withstand the loads and forces imposed by the hoist
for
the rated load.
Abatement documentation must be submitted for items a-1 through a-15.

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employment and a place of employment which were free from
recognized hazards that
were causing or likely to cause death or serious physical harm to
employees in that employees
were exposed to the hazard of being pulled into and crushed by the
rotating parts of a pipe
threading machine:
a)Dept. 1450, KK29, on or about 5/12/99:  A Ridgid pipe threader, Model
535,
Serial #ECO9633ES was activated by a manually operated on/off switch that
would not automatically shut the machine off should the operator be
inadvertently caught up in the rotating parts.
b)Dept. 1450, K13, Central Maintenance, on or about 6/18/99:  A Ridgid pipe
threader, Model 535, Serial #375155 was activated by a manually operated
on/off switch that would not automatically shut the machine off should the
operator be inadvertently caught up in the rotating parts.
c)Dept. 1450, E5, on or about 6/21/99:  A Ridgid pipe threader, Model 535,
Serial #ECO1776 was activated by a manually operated on/off switch that
would not automatically shut the machine off should the operator be
inadvertently caught up in the rotating parts.
Among other methods, one feasible method to reduce this hazard is to
install a
momentary contact device (deadman foot switch) to control power input to
the
machine.  This device would automatically stop the machine and the
rotating parts
if the operator's foot was removed from the foot switch for any reason.

Issued

Oct 26, 1999

Abate by

Jun 24, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $4,500 · Current $3,375 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800 · Current $1,350 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800 · Current $1,350 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Jan 2, 2001

Penalty

Initial $4,500 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Jan 2, 2001

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $4,500 · Current $3,375 Reduced

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Penalty

Initial $1,350 · Current $1,013 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,350 · Current $1,013 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Nov 29, 1999

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Issued

Oct 26, 1999

Abate by

Nov 29, 1999

Issued

Oct 26, 1999

Abate by

Nov 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Nov 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Mar 7, 2000

Penalty

Initial $4,500 · Current $3,375 Reduced

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Penalty

Initial $4,500 · Current $3,375 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800 · Current $1,350 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Penalty

Initial $1,147 · Current $860 Reduced

Issued

Oct 26, 1999

Abate by

Sep 14, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800 · Current $1,350 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800 · Current $1,350 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Nov 29, 1999

Penalty

Initial $2,250 · Current $1,688 Reduced

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Penalty

Initial $1,800

Issued

Oct 26, 1999

Abate by

Jan 3, 2000

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999

Issued

Oct 26, 1999

Abate by

Oct 29, 1999