OSHA Inspection: LONE STAR BAKERY, INC.

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $5500.00 · Current $3850.00 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer
does not
furnish employment and a place of employment which are free from recognized haza
rds that are causing or likely to cause death or serious physical harm to employ
ees in that employees are exposed to the hazards of falling from elevation: The
employer provides employees with personal fall arrest and/or restraint systems w
hich are not of safe design and construction for cleaning oven tops (to include
inadequate anchor points and improper lanyards, and body belts used in lieu of b
ody harnesses) and for cleaning silo tops (to include inadequate anchor points a
nd improper lanyards). a)Plant #1, Oven 1: On or about January 8, 2011, and time
s prior thereto on oven 1 where employee(s) wear a body harness or body belt, wr
apped their lanyard around natural gas line and connected back onto itself while
cleaning or performing maintenance on top of the oven from an elevation of 6' 3
". b)Plant #1, Oven 2: On or about January 8, 2011, and times prior thereto on o
ven
2, where employee(s) wear a body harness or body belt, wrapped their lanyard aro
und a natural gas line and connected back onto itself while cleaning or performi
ng maintenance on top of the oven from an elevation of 6' 3". c)Plant #1, Oven 3
: On or about January 8, 2011, and times prior thereto on oven 3, where employee
(s) wear a body harness or body belt, wrapped their lanyard around a natural gas
line and connected back onto itself while cleaning or performing maintenance on
top of the oven from an elevation of 6' 3". d)Plant #1, Flour Room Cake Silo A/
B: On or about January 8, 2011, and times prior thereto on the cake silo, where
employee(s) wrapped their lanyard around the top railing of the guardrail system
and connected it back onto itself while cleaning the top of the silo containing
flour where they were exposed to an engulfment hazard in the event of a fall th
rough a 36-inch wide sock opening in the top of the silo.
e)Plant #1, Flour Room Bread Silo A: On or about January 8, 2011, and times prio
r thereto on the cake silo, where employee(s) wrapped their lanyard around the t
op railing of the guardrail system and connected it back onto itself while clean
ing the top of the silo containing flour where they were exposed to an engulfmen
t hazard in the event of a fall through a 36-inch wide sock opening in the top o
f the silo. f)Plant #1, Flour Room Bread Silo B: On or about January 8, 2011, an
d times prior thereto on the cake silo, where employee(s) wrapped their lanyard
around the top railing of the guardrail system and connected it back onto itself
while cleaning the top of the silo containing flour where they were exposed to
an engulfment hazard in the event of a fall through a 36-inch wide sock opening
in the top of the silo. AMONG OTHER FEASIBLE METHODS TO CORRECT THE IDENTIFIED H
AZARD, ONE METHOD WOULD BE TO INSTALL ANCHOR POINTS PER ANSI Z359.1 SAFETY REQUI
REMENTS FOR PERSONAL FALL ARREST SYSTEMS, SUBSYSTEMS, AND COMPONENTS. ANOTHER ME
ANS OF ABATEMENT WOULD BE TO USE A SINGLE
ENTRY MOBILE STAIRS OR SCISSOR LIFT AND A BROOM EXTENSION ALLEVIATING THE NEED T
O CLIMB ON THE OVENS. IN THE ALTERNATIVE: 29 CFR 1910.132(c): Protective equipme
nt is not of safe design and construction for the work to be performed: The empl
oyer provides employees with personal fall arrest and/or restraint systems which
are not of safe design and construction for cleaning oven tops (to include inad
equate anchor points and improper lanyards, and body belts used in lieu of body
harnesses) and for cleaning silo tops (to include inadequate anchor points and i
mproper lanyards). a)Plant #1, Oven 1: On or about January 8, 2011, and times pr
ior thereto in on oven 1 where employee(s) wear a body harness or body belt, wra
pped their lanyard around natural gas line and connected back onto itself while
cleaning or
performing maintenance on top of the oven from an elevation of 6' 3". b)Plant #1
, Oven 2: On or about January 8, 2011, and times prior thereto on oven 2, where
employee(s) wear a body harness or body belt, wrapped their lanyard around a nat
ural gas line and connected back onto itself while cleaning or performing mainte
nance on top of the oven from an elevation of 6' 3". c)Plant #1, Oven 3: On or a
bout January 8, 2011, and times prior thereto on oven 3, where employee(s) wear
a body harness or body belt, wrapped their lanyard around a natural gas line and
connected back onto itself while cleaning or performing maintenance on top of t
he oven from an elevation of 6' 3". d)Plant #1, Flour Room Cake Silo A/B: On or
about January 8, 2011, and times prior thereto on the cake silo, where employee(
s) wrapped their lanyard around the top railing of the guardrail system and conn
ected it back onto itself while cleaning the top of the silo containing flour wh
ere they were exposed to an
engulfment hazard in the event of a fall through a 36-inch wide sock opening in
the top of the silo. e)Plant #1, Flour Room Bread Silo A: On or about January 8,
2011, and times prior thereto on the cake silo, where employee(s) wrapped their
lanyard around the top railing of the guardrail system and connected it back on
to itself while cleaning the top of the silo containing flour where they were ex
posed to an engulfment hazard in the event of a fall through a 36-inch wide sock
opening in the top of the silo. f)Plant #1, Flour Room Bread Silo B: On or abou
t January 8, 2011, and times prior thereto on the cake silo, where employee(s) w
rapped their lanyard around the top railing of the guardrail system and connecte
d it back onto itself while cleaning the top of the silo containing flour where
they were exposed to an engulfment hazard in the event of a fall through a 36-in
ch wide sock opening in the top of the silo.
Pursuant to 29 CFR 1903.19, within ten (10) calendar days, the employer must sub
mit an abatement plan describing the actions it is taking to ensure employee(s)
are not exposed to the hazards of falls while cleaning the tops of ovens and sil
os.

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $0.00 · Current $0.00

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $5500.00 · Current $3850.00 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer
does not furnish employment and a place of employment which are free from recogn
ized hazards that are causing or likely to cause death or serious physical harm
to employees in that employees are exposed to the hazards of falling from elevat
ion: The employer does not provide a safe means of access and egress to the top
of the oven. a)Plant #1, Oven 1: On or about January 8, 2011, and times prior th
ereto on oven 1 where employee(s) were exposed to falls from a height of 6' 3" t
o the concrete floor below, while accessing and descending from a 6' Werner fibe
rglass ladder to/from the top of the oven.
b)Plant #1, Oven 2: On or about January 8, 2011, and times prior thereto on oven
2 where employee(s) were exposed to falls from a height of 6' 3" to the concret
e floor below, while accessing and descending from a 6' Werner fiberglass ladder
to/from the top of the oven. c)Plant #1, Oven 3: On or about January 8, 2011, a
nd times prior thereto on oven 3 where employee(s) were exposed to falls from a
height of 6' 3" to the concrete floor below, while accessing and descending from
a 6' Werner fiberglass ladder to/from the top of the oven. AMONG OTHER METHODS,
FEASIBLE AND ACCEPTABLE ABATEMENT METHODS TO CORRECT THIS HAZARD ARE TO: 1) USE
THE SINGLE ENTRY MOBILE STAIRS TO GAIN ACCESS TO THE TOP OF THE OVEN. 2) AN ALT
ERNATIVE COULD BE TO USE THE WERNER SELF SUPPORTING LADDER BY TYING IT OFF TO TH
E STRUCTURE TO PREVENT SIDEWAYS MOTION AS PER ANSI A14.5-2007 WHICH IS ATTACHED.
Pursuant to 29 CFR 1903.19, within ten (10) calendar days, the employer must sub
mit an abatement plan describing the actions it is taking to ensure safe access
to the top of oven 1, oven 2, and oven 3.

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer
does not furnish employment and a place of employment which are free from recogn
ized hazards of lack of electrical bonding in material transportation systems fo
r combustible dust, increasing the risk of fire, explosion, and/or deflagration,
which are likely to cause death or serious physical harm to employees: The empl
oyer does not provide electrical bonding across the entire length of the sight g
lass. a)Plant #1, Outside Silo Flour Transfer System Outside Sight Glass (A): Th
is
violation was observed on or about January 18, 2011, and at times prior thereto,
employee(s) were exposed to fires and explosions that can occur when combustibl
e flour dust was transported through a material processing system that is not pr
operly bonded across the sight glass. b)Plant #1, Outside Silo Flour Transfer Sy
stem Outside Sight Glass (B): This violation was observed on or about January 18
, 2011, and at times prior thereto, employee(s) were exposed to fires and explos
ions that can occur when combustible flour dust was transported through a materi
al processing system that is not properly bonded across the sight glass. c)Plant
#1, Flour Room Flour Transfer System Inside Sight Glass (A): This violation was
observed on or about January 18, 2011, and at times prior thereto, employee(s)
were exposed to fires and explosions that can occur when combustible flour dust
was transported through a material processing system that is not properly bonded
across the sight glass.
d)Plant #1, Flour Room Flour Transfer System Inside Sight Glass (B): The employe
r does not provide electrical bonding across the entire length of the sight glas
s. This violation was observed on or about January 18, 2011 and at times prior t
hereto, employee(s) were exposed to fires and explosions that can occur when com
bustible flour dust was transported through a material processing system that is
not properly bonded across the sight glass. AMONG OTHER FEASIBLE AND ACCEPTABLE
ABATEMENT METHODS TO CORRECT THIS HAZARD ARE TO FOLLOW NFPA 61-2008 SECTION 11.
2.2 PNEUMATIC CONVEYING SYSTEMS GENERAL DESIGN AND NFPA 654-2006 SECTION 7.7.7 T
O ENSURE THAT ELECTRICAL BONDING ACROSS THE LENGTH OF THE SIGHT GLASS ON EACH MA
TERIAL PROCESS TRANSFER PIPING SYSTEM IS CONTINUOUS AND HAS A RESISTANCE OF NOT
MORE THAN ONE (1) OHM. Pursuant to 29 CFR 1903.19, within ten (10) calendar days
, the employer must submit an abatement plan describing the actions it is taking
to ensure that the employer is following NFPA
61-2008 Section 11.2.2 and NFPA 654-2006 Section 7.7.7.

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $3300.00 · Current $2310.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $0.00 · Current $0.00

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $0.00 · Current $0.00

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $5500.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-05-04 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $3000.00 · Current $2310.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $5000.00 · Current $3850.00 Reduced

Issued

2011-04-08 00:00:00

Abate by

2011-08-15 00:00:00

Penalty

Initial $7000.00 · Current $4900.00 Reduced