OSHA Inspection: PERFECT PATTERNS, INC.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $4900.00 · Current $4000.00 Reduced

Hazardous substances 9010

General-duty citation text

29 CFR 1910.94(a)(2)(ii):     The concentration of respirable dust or fume in the breathing zone of the abrasive-blasting operator or any other worker shall be kept below the levels specified in 1910.1000.    On 02/22/2012, Shot Blast Operators and a Forklift/Floor Sweep Operator were exposed to concentrations of respirable crystalline silica dust in excess of the permissible exposure limits specified in 1910.1000 Table Z-3 from the Shot Blast enclosure in the north portion of the facility.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9010

General-duty citation text

29 CFR 1910.94(b)(5)(iv):    Portable grinding operations were not conducted within exhausted partial enclosures maintaining an average face air velocity not less than 200 feet per minute:    On 02/22/2012, employees working at Grinder stations on Lines #1-3 were conducting portable grinding operations in stations that were not partially exhausted enclosures when working with handheld pneumatic grinders, chippers and polishers, average face air velocities were less than 200 feet per minute.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 9010

General-duty citation text

29 CFR 1910.134(a)(2):     A respirator was not provided by the employer to each employee when such equipment was necessary to protect the health of the employee:    On 02/22/2012, Grinder employees, Shot Blast Operators and a Forklift/Floor Sweep Operator were exposed to respirable crystalline silica concentrations exceeding the 8-hour time weighted average (TWA). The employer did not provide appropriate respirators to each employee while engineering controls were being instituted.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1000(c):     Employees were exposed to respirable crystalline quartz silica dust in excess of the 8-hour time weighted average (TWA) as listed in Table Z-3:    The following employees were exposed to respirable crystalline silica at levels in excess of the permissible exposure limit (PEL):    a)  A Grinder employee on Line #3, who was exposed to airborne respirable dust containing 14% crystalline silica at levels of 1.60 mg/m3 as an 8-hour TWA, approximately 2.6 times the PEL of 0.625 mg/m3.    b)  A Grinder employee on Line #3, who was exposed to airborne respirable dust containing 10% crystalline silica at levels of 0.92 mg/m3 as an 8-hour TWA, approximately 1.1 times the PEL of 0.833 mg/m3.    c)  A Grinder employee on Line #2, who was exposed to airborne respirable dust containing 8.0% crystalline silica at levels of 2.10 mg/m3 as an 8-hour TWA, approximately 2.1 times the PEL of 1.0 mg/m3.    d)  A Grinder employee on Line #1, who was exposed to airborne respirable dust containing 25% crystalline silica at levels of 3.50 mg/m3 as an 8-hour TWA, approximately 9.5 times the PEL of 0.370 mg/m3.    e)  A Grinder employee on Line #1, who was exposed to airborne respirable dust containing 16% crystalline silica at levels of 1.30 mg/m3 as an 8-hour TWA, approximately 2.3 times the PEL of 0.556 mg/m3.    f)  A Grinder employee on Line #1, who was exposed to airborne respirable dust containing 11% crystalline silica at levels of 1.40 mg/m3 as an 8-hour TWA, approximately 1.8 times the PEL of 0.769 mg/m3.    g)  A Shot Blast Operator, who was exposed to airborne respirable dust containing 9.1% crystalline silica at levels of 1.30 mg/m3 as an 8-hour TWA, approximately 1.4 times the PEL of 0.901 mg/m3.    h)  A Shot Blast Operator, who was exposed to airborne respirable dust containing 11% crystalline silica at levels of 3.30 mg/m3 as an 8-hour TWA, approximately 4.3 times the PEL of 0.769 mg/m3.    i)  A Forklift/Floor Sweep Operator, who was exposed to airborne respirable dust containing 14% crystalline silica at levels of 1.20 mg/m3 as an 8-hour TWA, approximately 1.9 times the PEL of 0.625 mg/m3.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.1000(e):     Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d):    On 02/22/2010, feasible administrative or engineering controls were not determined and implemented in order to reduce employees' exposure to concentrations of respirable crystalline quartz silica to limits prescribed in 1910.1000(c) Table Z-3.    Applicable administrative or engineering controls may include, but are not limited to the following:    1)  Train employees to position their work so that the dust and swarth generated by grinding activities is directed to the exhaust capture hood.    2)  Ensure powered industrial vehicle movement, housekeeping operations and floor sweeping do not generate airborne dust.    3)  Redesign the exhaust capture hoods on Grinder stations to partially enclose the grinding work and maintain a face air velocity of no less than 200 feet per minute or redesign the Grinder stations to downdraft tables.    4)  Ensure the Shot Blast is properly sealed, the ventilation is adequate and efficient and/or add additional dust collection to efficiently capture silica dust before it escapes the Shot Blast and enters the work area.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2014-04-14 00:00:00

Penalty

Initial $4900.00 · Current $4000.00 Reduced

General-duty citation text

29 CFR 1910.95(b)(1):     When employees were subjected to sound exceeding those listed in Table G-16, feasible engineering controls were not utilized:    On 02/22/2012, employees were exposed to noise levels exceeding the 8-hour time weighted average (TWA) of 90 dBA:    a)  Stand Grinder Operator, on Line #3 was exposed to noise at a TWA of 96.74 dBA over a 459 minute sample time. 96.74 dBA is over 2.5 times the allowable exposure to noise.    b)  Grinder employee, on Line #2 was exposed to noise at a TWA of 96.40 dBA over a 204 minute sample time. 96.40 dBA is over 2 times the allowable exposure to noise.    c)  Grinder employee, on Line #1 was exposed to noise at a TWA of 99.43 dBA over a 447 minute sample time. 99.43 dBA is over 3.5 times the allowable exposure to noise.    d)  Inspector employee, on Lines #1-3 was exposed to noise at a TWA of 95.68 dBA over a 463 minute sample time. 95.68 DBA is over 2 times the allowable exposure to noise.    Applicable engineering or administrative controls may include, but are not limited to the following:    1)  Use separation of distance between each Grinder station and Stand Grinder stations to reduce the noise exposure each station receives from neighboring grinding operations.    2)  Purchase pneumatic equipment designed to produce less noise from air exhausting and/or install mufflers in pneumatic equipment to reduce noise from air exhausting.    3)  Install noise dampening pads (such as rubber) on hard reverberating surfaces such as the rollers castings sit on for grinding as well as sheet metal walls surrounding ventilation openings to reduce the noise exposure an operator imparts on themselves.    4)  Install noise depending barriers between stations to reduce the noise exposure each station receives from neighboring grinding operations and to reduce the noise exposure an operator imparts on themselves.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2012-05-04 00:00:00

Penalty

Initial $4900.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.95(c)(1):     The employer did not administer a continuing, effective hearing conservation program as described in 29 CFR 1910.9(c) through (o) whenever employee noise exposures equal or exceed an 8-hour time-weighted average sound level of 85 decibels measured on the A scale, or equivalently a dose of fifty percent:    On 02/22/2012, the employer did not administer a continuing or effective hearing conservation program when employees were exposed to noise levels exceeding the 8-hour time weighted average (TWA) of 85 dBA:    a)  Stand Grinder Operator, on Line #3 was exposed to noise at a TWA sound level of 96.76 dBA over a 459 minute sample time.    b)  Grinder employee, on Line #2 was exposed to noise at a TWA sound level of 96.42 dBA over a 204 minute sample time.     c)  Grinder employee, on Line #1 was exposed to noise at a TWA sound level of 99.44 dBA over a 447 minute sample time.    d)  Shot Blast Operator, in the shot blast area was exposed to noise at a TWA sound level of 90.37 dBA over a 463 minute sample time.     e)  Inspector employee, on Lines #1-3 was exposed to noise at a TWA sound level of 95.79 dBA over a 463 minute sample time.     All provisions of 29 CFR 1910.95(c) through (n) must be covered in a hearing conservation program. Key elements include, but are not limited to the following:    1)  Noise level monitoring  2)  Audiometric testing  3)  Wearing of hearing protectors  4)  Training program  5)  Providing copies of standard to employees  6)  Recordkeeping    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2012-05-04 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 8111

General-duty citation text

29 CFR 1910.95(k)(1):     The employer did not train each employee who is exposed to noise at or above an 8-hour time-weighted average of 85 decibels in accordance with the requirements of 29 CFR 1910.95(k). The employer did not institute a training program and ensure employee participation in the program:    On 02/22/2012, the employer did not institute a noise training program or train employees who were exposed to noise levels above the 8-hour time weighted average (TWA) of 85 dBA such as a Stand Grinder Operators, Grinder employees, Shot Blast Operators and Inspectors.     ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2012-06-24 00:00:00

Penalty

Initial $4900.00 · Current $3500.00 Reduced

General-duty citation text

29 CFR 1910.134(c)(1):     A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:    On 02/22/2012, the employer had not developed or implemented a written respiratory protection program where respirators were necessary to protect Grinder employees, Shot Blast Operators and a Forklift/Floor Sweep Operator from exposure to respirable crystalline silica at concentrations above the permissible exposure limit as listed in 1910.1000(c) Table Z-3.    All provisions of 29 CFR 1910.134(c) through (m) must be covered in a written respiratory protection program. Key elements include, but are not limited to the following:    1)  Respirator selection  2)  Medical evaluations  3)  Fit testing  4)  Use, maintenance and care of respirators  5)  Employee information and training  6)  Program evaluation    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.

Issued

2012-03-26 00:00:00

Abate by

2012-04-16 00:00:00

Penalty

Initial $595.00 · Current $0.00 Reduced

General-duty citation text

29 CFR 1910.132(d)(2):     The employer did not verify that the required workplace hazard assessment had been performed through written certification that identified the workplace evaluated; the person certifying that the evaluation had been performed; the date(s) of the hazard assessment; and, identified the document as a certification of the hazard assessment:    On 12/07/2011, the employer did not verify that a workplace hazard assessment had been performed through written certification to determine what personal protective equipment was necessary to protect employees from hazards such as flying particles, respirable dust and noise.    ABATEMENT CERTIFICATION AND ABATEMENT DOCUMENTATION REQUIRED.