OSHA Inspection: FRANCIS MANUFACTURING COMPANY

Issued

Jan 28, 2009

Abate by

Jul 15, 2009

Penalty

Initial $1,750 · Current $875 Reduced

Hazardous substances G301M110M103M102S102

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 dust explosion, deflagration, or other fire hazards
because methods were not
utilized to ensure proper collection of and prevent ignition of
combustible aluminum dusts during
the generation, handling and collection operations:
a.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the dust collector for the finishing
department was located
outside of the building, prohibited the recycling of air back into the
work environment,
and had not provided the dust collector with deflagration isolation
devices to prevent
deflagration propagation from the dust collector to the upstream work
area.  The
aluminum dust entering the dust collector had a kst value of 7.48 bm/sec
and was
classified as an explosive dust.
ABATEMENT NOTE: Among other methods, one feasible and acceptable abatement
method
to correct this hazard is to comply with National Fire Protection
Association (NFPA) 484
"Standard for Combustible Metals" (2006); NFPA 69 "Standard on Explosion
Prevention
Systems" (2008), including, but not limited to: a) Install a deflagration
detection and suppression
system in accordance with Chapter 9 of NFPA 69.  b) Relocate the dust
collection equipment
to an outside location and prohibit the recycling of air from the dust
collection system back into
the work environment in accordance with Chapter 6 of NFPA 484. c) When
locating the dust
collector outside, provide deflagration venting to a safe location per
NFPA 484 (section 6.3.5.6).
In accordance with 29 CFR 1903.19(d), abatement certification is required
for
this violation
(using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition,
documentation demonstrating that abatement is complete must be included
with your
certification.  This documentation may include, but is not limited to,
evidence of the purchase
or repair of the equipment, photographic or video evidence of abatement,
or other written
records.

Issued

Jan 28, 2009

Abate by

Feb 17, 2009

Penalty

Initial $1,750 · Current $875 Reduced

Hazardous substances G301M110M103M102S102

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 aluminum dust explosions and fires in the
shipping/receiving area when dust
clouds were created during dust collector filter cleaning operations, when
cleaning-up aluminum
dust without the use of nonsparking tools, and when improperly storing
aluminum dust in open-
top steel drums:
a.Francis Manufacturing Company located in Russia, Ohio:  On or about
August
13, 2008,
the employer did not ensure dust clouds were not generated while removing
and cleaning
the dust collector filter cartridges.  The employee removed the circular
access doors for
each filter cartridge and allowed accumulated aluminum dust to fall to the
floor.  The
employee then removed the filter cartridges from the collector and bumped
the cartridge
on the floor to dislodge the dust from the filter cartridge.
b.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure employees used nonsparking tools when cleaning
up
aluminum dust from the floor after dislodging the dust from the filter
cartridges.
Employees used a steel shovel to scoop the material into a steel storage
drum.
c.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure aluminum dust storage drums were promptly and
tightly
covered.  Aluminum dust was disposed into the open-top storage drums on a
daily basis
and removed from the facility every two weeks.
ABATEMENT NOTE:Among other methods, one feasible and acceptable abatement
method to
correct this hazard is to comply with National Fire Protection Association
(NFPA) 484 "Standard
for Combustible Metals" (2006), including but not limited to: a) Ensuring
dust clouds are not
created while removing and cleaning filter cartridges in accordance with
Chapter 6 of NFPA
484. b) Ensuring nonsparking tools and natural bristle brushes are used to
clean-up aluminum
dust in accordance with Chapter 6 of NFPA 484. c) Ensuring aluminum dust
is stored in a
tightly covered container in accordance with Chapter 6 of NFPA 484. d)
Ensuring that dust from
the interior of the hatchway cover on the dust collector is vacuumed or
otherwise collected prior
to filter cartridge removal. e) Ensuring that filters are pulsed, rotated
inside the cabinet and
pulsed again to remove dust from filter prior to removal from the
collector per manufacturer
guidelines.
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this violation
(using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition,
documentation demonstrating that abatement is complete must be included
with your
certification.  This documentation may include, but is not limited to,
evidence of the purchase
or repair of the equipment, photographic or video evidence of abatement,
or other written
records.

Issued

Jan 28, 2009

Abate by

Mar 3, 2009

Penalty

Initial $1,750 · Current $875 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 melting
furnaces #8, #9 and #1 were not equipped with flame supervision which
would ensure the fuel
flow would be interrupted if the burner flame were to be extinguished:
a.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the natural gas fired melting furnace #8 was
equipped with
flame supervision (flame out protection) which would ensure the fuel flow
would be
interrupted if the furnace's burner flame were to be extinguished.
b.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the natural gas fired melting furnace #9 was
equipped with
flame supervision (flame out protection) which would ensure the fuel flow
would be
interrupted if the furnace's burner flame were to be extinguished.
c.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the natural gas fired melting furnace #1 was
equipped with
flame supervision (flame out protection) which would ensure the fuel flow
would be
interrupted if the furnace's burner flame were to be extinguished.
ABATEMENT NOTE: Among other methods, one feasible and acceptable method to
correct
this hazard is to comply with National Fire Protection Association (NFPA)
86 "Standard for
Ovens and Furnaces" (2003), including but not limited to each burner being
supervised by
combustion safeguards that have the maximum flame failure response time of
4 seconds or less,
that perform a safe-start check, and that are interlocked into the
combustion safety circuitry in
accordance with Chapter 7 of NFPA 86.
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this violation
(using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition,
documentation demonstrating that abatement is complete must be included
with your
certification.  This documentation may include, but is not limited to,
evidence of the purchase
or repair of the equipment, photographic or video evidence of abatement,
or other written
records.t,

Issued

Jan 28, 2009

Abate by

Feb 17, 2009

Penalty

Initial $1,750 · Current $875 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 the backup
alarms for the skid steer loader #LMV002211 and #LMV024948 used in the
foundry were not
equipped with functioning backup alarms, exposing employees to struck by
hazards:
a.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the New Holland skid steer Serial #002211 was
equipped
with a functioning backup alarm.  The loader is used to move sand in
various parts of
the foundry directly adjacent to where other foundry employees are
working.
b.Francis Manufacturing Company located in Russia, Ohio:  On or about
August 13, 2008,
the employer did not ensure the New Holland skid steer Serial #024948 was
equipped
with a functioning backup alarm. The loader is used to move sand in
various parts of the
foundry directly adjacent to where other foundry employees are working.
ABATEMENT NOTE: Among other methods, one feasible and acceptable method to
correct
this hazard is to comply with the Association of Equipment Manufacturers
(AEM) [Skid Steer]
2004, "Safety Manual for Operating and Maintenance Personnel", including
but not limited to
ensuring the backup alarm is in place and in operating condition.
In accordance with 29 CFR 1903.19(d), abatement certification is required
for this violation
(using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition,
documentation demonstrating that abatement is complete must be included
with your
certification.  This documentation may include, but is not limited to,
evidence of the purchase
or repair of the equipment, photographic or video evidence of abatement,
or other written
records.

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Penalty

Initial $1,750 · Current $1,000 Reduced

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Penalty

Initial $1,400

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Penalty

Initial $3,500 · Current $1,750 Reduced

Issued

Jan 28, 2009

Abate by

Feb 17, 2009

Issued

Jan 28, 2009

Abate by

Feb 9, 2009

Issued

Jan 28, 2009

Abate by

Feb 27, 2009