OSHA Inspection: KOHLER CO.

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $3,740 · Current $2,618 Reduced

General-duty citation text

29 CFR 1910.22(a)(1):     All places of employment, passageways, storerooms or service rooms were not kept clean and orderly or in a sanitary condition.    a)    Decks, catwalks, and walkways above main floor for Herman line had electrical cords, hoses, other materials and sand of up to 9" deep on them presenting tripping or stumbling hazards.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Mar 28, 2012

Penalty

Initial $5,610 · Current $3,927 Reduced

General-duty citation text

29 CFR 1910.94(a)(5)(v):     Operators were not equipped with heavy canvas or leather gloves or equivalent protection to protect them from the impact of abrasives.     a)    Ruemelin abrasive blasting cabinet (No. 32742) had torn sleeves with missing gloves.     ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Jun 22, 2012

Penalty

Initial $5,610 · Current $3,927 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):     One or more methods of machine guarding was not provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    a)   The Collecting Belt conveyor had inadequately guarded ingoing nip points, with expanded metal guard bent over allowing 2 1/2" gap.    b)    The Collecting Belt conveyor guard for ingoing nip points left an 9" x 15" gap to reach nip point which was approximately 7" from the frame.    c)    At the Herman, 24' level, the Muller had approximately a 4" x 5" hole in one of the guards with sharp edges.    d)    At the 12' level, North Bold Car Room, ingoing nip points on belt conveyor were not guarded and had open access.    e)    At the #3 spill sand belt conveyor, an unguarded ingoing nip point was approximately 10" from frame.    f)    The Marvel 916 M horizontal band saw, the unused portion of the blade was not guarded.  9" was exposed to the left and 3" to the right.    g)    At Core Machine 7G#4, the operator was exposed to a ingoing nip on the conveyor belt, with a 2" gap on operator side.    h)    At Core machine 7G#3, there was an approximately 10" x 6" hole in the guard, with 4" distance to balance arm pinch point.    i)    At Core machine 7G#3, the operator was exposed to an ingoing nip on conveyor belt, with a 2 1/2" gap on operator side.    j)    At the Osborn, the blast roll over area not guarded, with approximately 16" from the shaft end to rollover mechanism.    k)   At the Herman line, under the steps near A135 control panel, the flask pusher pinch point was not guarded.    l)    The Closer system had large hydraulic cylinder closing/crushing point not guarded on south side of the platform approximately 20" from railing.    m)   At the North feeder belt for the conveyor on the deck with 15A/1 vibrator disconnect, the ingoing nip point was not adequately guarded with approximately 9" to ingoing nip from frame.    n)    North side flask shaker created pinch and amputation points with nothing to block access to the hazard area..    o)    At the Pattern loop break station, an unguarded shear point was 50" above the chair where employee sits.    p)    At the #3 wheel abrator line, the conveyor advances automatically without nip point guarding.    q)    An employee was sweeping under the elevator with it up, and then lowering without chain hooked to prevent crushing injury.    r)    At Conveyor 2000, pinch points were not guarded below the conveyor.    s)    At Conveyor 1100  pinch point were created with rotating table at eight work stations.    t)    At the Tum Blast Shaker elevator, pinch points were not guarded.    x)    At the Tum blast bucket dumping area, guarding was not adequate to keep people out of are of hazard during operation.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Jun 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.212(a)(3)(ii):     Point of operation guards were not designed and constructed as to prevent the operator from having any part of their body in the danger zone during the operating cycle:    a)    Elevator on west end of building, 056-1005, #1, Pinch points exposed under guard when elevator operates with approximately 13" exposed between guard and floor.    b)    Elevator West, SB, approximately 12 1/2" gap under slide guard exposing pinch points when elevator operates. Slide guard did not reach the 7' height so there was also a pinch point created at the top of the guard when elevator operated.     c)    Core machines 7G#4 & 7G#3, back side of core machines is not guarded to protect points of operation.    d)    Osborn molding machine, closer side, guarding to prevent entry during points of operation was not adequate.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $4,675 · Current $3,273 Reduced

General-duty citation text

29 CFR 1910.219(c)(4)(i):     Unguarded projecting shaft end(s) did not present a smooth edge and end and projected more than one half the diameter of the shaft:    a)    Collecting belt conveyor had a 3" diameter shaft projecting out 4" without a guard.    ABATEMENT CERTIFCATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(d)(1):     Pulley(s) with part(s) seven feet or less from the floor or work platform were not guarded in accordance with the requirements specified in 29 CFR 1910.219(m) and (o):    a)    Core machine 7G#4, the drive belt and pulley for the conveyor were not guarded on backside.    b)    Osborn air compressor room, the air compressor belts and pulley were not guarded on backside.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(e)(3)(i):     Vertical or inclined belt(s) were not enclosed by guard(s) conforming to the requirements specified at 29 CFR 1910.219(m) and (o):    a)    Core machine 7G#4, the drive belt and pulley for the conveyor were not guarded on the backside.    b)    Osborn air compressor room, the air compressor belts and pulleys were not guarded on the backside.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.219(f)(3):     Sprocket wheels and chains which were seven -7 feet or less above floors or platforms were not enclosed:    a)   A damaged guard left a partially exposed chain and sprocket nip point on CRC lower tub coveyor, Herman.    b)    Herman line, apron feeder chain and sprocket had an unguardedinrunning nip point approximately 18" from chute frame to nip point.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Mar 28, 2012

Penalty

Initial $4,675 · Current $3,273 Reduced

General-duty citation text

29 CFR 1910.253(b)(4)(i):     Oxygen cylinders were stored near highly combustible material, especially oil and grease; or near reserve stocks of carbide and acetylene or other fuel-gas cylinders, or near other substance likely to cause or accelerate fire:    a)    Melt maintenance shop, oxygen and acetylene tanks were stored side by side in designated storage area.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 12, 2012

Penalty

Initial $4,675 · Current $3,273 Reduced

General-duty citation text

29 CFR 1910.254(b)(4)(iv):     Terminals for welding leads were not protected from accidental contact by personnel or metal objects:    a)    Herman area, Miller SRH-303 portable ARC welder did not have welding leads protected.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 12, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.254(d)(9)(iii):     Cables with damaged insulation or exposed bare conductors were not replaced:    a)    Cables with damaged insulation and bare conductors on Miller SRH-303 ARC welder in Herman area.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $4,675 · Current $3,273 Reduced

General-duty citation text

29 CFR 1910.303(f)(1):     Each disconnecting means required by Subpart S of Part 1910 for motors and appliances was not legibly marked to indicate its purpose, nor located and arranged so the purpose was evident:    a)    Melt control tower, N wall, control room, disconnect was not labeled next to charge crane rail system.    b)    Charge floor, east end, near door, Square D disconnect was not labeled.    c)    Charge floor, North side of door, Allen Bradley disconnect was not labeled.    d)    North wall of core room, two unlabeled Square D disconnects.    e)    West side of core room office, an unlabeled Square D diconnect.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 2, 2012

Penalty

Initial $2,805 · Current $1,964 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(B):     Flexible cords and cables were run through holes in walls, ceilings, or floors:    a)    Hotel furnace hydraulic room, electrical cable was running through hole in cement wall.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $3,740 · Current $2,618 Reduced

General-duty citation text

29 CFR 1910.1200(f)(5)(i):     The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the identity of the hazardous chemical(s) contained therein:    a)    Melt maintenance shop, parts washer was labeled with the chemical company but not the identity of the solvent.    b)    Vertical core machine area, dip tank was not labeled.    c)    Melt control room,  a spray bottle was labeled "APC" with Simple Green chemical in it.

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(f)(5)(ii):     The employer did not ensure that each container of hazardous chemicals in the workplace was labeled, tagged or marked with the appropriate hazard warnings:    a)    Vertical core machine dip tank did not have a chemical hazard warning label.    b)    Foundry metal laboratory had small plastic bottles of Nital, alcohol and actone without chemical hazard warning labels.    c)    Melt maintenance shop, parts washer was labeled with the chemical company but not the identity of the solvent.    d)    Melt control room,  a spray bottle was labeled "APC" with Simple Green chemical in it.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED

Issued

Mar 23, 2012

Abate by

Apr 22, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.215(b)(9):     The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:    a)    1806 CINCI pedestal grinder, tongue guard was out of adjustment. Approximately 1 1/2" of clearance from wheel to safety guard.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED