OSHA Inspection: FORD MOTOR CO., CASTING PLANT

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $7,000 · Current $7,000

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.  On several occasions the presence of water created hazardous
conditions, including the
potential for explosions.  These instances included but were not limited
to
the following:
1.  On 5-21-98 the cleaning station quench tank in the 4.6 liter
department had its water
leaking down into the basement of the #3 automated pouring line.  This was
occurring in
conjunction with the molten metal dumping into the pit of the #3 automated
pouring line.  The
practice of dumping molten metal into the pit needs to be reviewed not
only because no warning
device was in use to clear the pit of any employee, but there was no
system in place to ensure
that the pit did not contain any water.  Had the water from the cleaning
quench tank migrated
to the pit (towards which the water was moving) the conditions would have
been present for a
molten metal explosion.
A feasible method of abatement includes, but is not limited to, ensuring
that the dump pit is free
of moisture which could become entrapped by the dumped molten metal
resulting in an
explosion.
2.  On 6-4-98 the #3 cupola had a leaking water hose at its cooler run off
area creating
a collection of water around the cupola.  In the event of a hot spot
run-out this situation created
the potential for an explosion.
A feasible method of abatement includes, but is not limited to, repairing
the leaking hose and
cleaning the area of all water.
3.  On 6-23-98 the #7 holding furnace, established to be full, had water
dripping into its
overpour pit directly beneath the furnace.  Likewise, the flooring all
around the #7 furnace and
the #7 cupola was wet from the events of 6-22-98 during which the slushway
system overflowed.
This occurred in conjunction with the discovery of a hot-spot on the #7
cupola.
A feasible method of abatement includes, but is not limited to, shoring up
the
slushway to
prevent its overflow.
4.  On 6-30-98 the melt department had water throughout the department,
particularly
on the front and back aisles of the #7 cupola and #7 holding furnace.
A feasible method of abatement includes, but is not limited to, cleaning
up the water by mopping
and absorption methods and by way of sump pumps for areas holding water.
5.  On 6-4-98 the storage of the calcium carbide in the loft at the east
end of the melt
department is in proximity to the department's water coolant circulating
unit, piping, and tanks
located at the east end within 15 feet of the calcium carbide totes.
6.  The run-off bins behind the #7 furnace are taken out of the melt
department by way
of the main aisle of the pour department requiring the bins to pass the
standing water of the
cascading #7 cupola.  On 6-4-98 the run-off bins were positioned at the #7
furnace within 25
feet of standing water in the back aisle.  Any spillage or leaks could
cause the water to become
entrapped.

Issued

Nov 12, 1998

Abate by

Feb 18, 1999

Penalty

Initial $2,500 · Current $2,500

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.  On 6-3-98 the operators of the Shepherd Niles hot metal cranes were
using the upper limit
switches as their means of braking.  Operators relied on the limit
switches to bring their ladles
and their cabs to an upper stop.  The older model Shepherd Niles cranes do
not have mechanical
stops to prevent the units' cables from being sheared in the event the
limit switches fail.

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $7,000 · Current $7,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $7,000 · Current $7,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $3,500 · Current $3,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $1,500 · Current $1,500

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 17, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,000 · Current $2,000

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Penalty

Initial $2,500 · Current $2,500

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Nov 12, 1998

Abate by

Nov 18, 1998

Issued

Oct 12, 1998

Abate by

Oct 18, 1998

Penalty

Initial $2,500 · Current $2,500

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The
employer did not
furnish employment and a place of employment which were free from
recognized hazards that
were causing or likely to cause death or serious physical harm to
employees in that employees
were exposed to:
a.  On or before 5-15-98 Abell-Howe jib hoists throughout the plant were
in danger of having
their booms become disengaged from their masts due to the absence of
anti-lift devices.  These
units included but were not limited to the following:
1.  Unit #9224 in the tin shop (noted on 5-15-98).
2.  Unit #0784 in the maintenance shop at the end of the #5 core line
(noted on 5-15-98).
3.  Unit #9938 in the knockout house.
This condition exposed employees to being struck by the falling booms and
their attached hoists.
A feasible method of abatement includes, but is not limited to, attaching
devices which would
secure the booms and prevent them from being lifted off their bearings.
The manufacturer
provides various devices in order to accomplish this.  The manufacturer
could also possibly
provide alternate means of abatement as well as schematics of devices that
can be fabricated in-
house.