OSHA Inspection: WRENA, LLC

Issued

Jul 2, 2012

Abate by

Aug 1, 2012

Penalty

Initial $3,850 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.132(a):  Application. Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers, shall be provided, used, and maintained in a sanitary and reliable condition wherever it is necessary by reason of hazards of processes or environment, chemical hazards, radiological hazards, or mechanical irritants encountered in a manner capable of causing injury or impairment in the function of any part of the body through absorption, inhalation or physical contact:    (a)  Employees working on the Autojectors Vertical Injection Molding Machine #124, were exposed to a 5 foot fall while standing on the yellow bar and a 8 foot fall while standing on top of the machine.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $2,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii):  The procedures shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, the following:    (a)  The machine specific energy control procedure for locking out the Autojectors Vertical Injection Molding Machine #124 was incomplete and inaccurate, in that it required locking out a flywheel that did not exist, it required locking out a single pneumatic 1/4 inch ball valve where there were actually two valves, and it did not adequately address blocking the gravitational energy source of the ram.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i):  The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees:      (a)  Employees performing maintenance on the Cincinnati Vertical Injection Molding Machine #123 and the Autojectors Vertical Injection Molding Machine #124, were not adequately trained on the energy control program, in that they did not isolate and lock out the electrical disconnect, block the gravitational energy of the ram, and apply a lock to the pneumatic ball valves.     (b)  Employees setting up, adjusting, and cleaning the molds on the Cincinnati Vertical Injection Molding Machine #123 and the Autojectors Vertical Injection Molding Machine #124, were not adequately trained on the energy control program, in that they did not isolate and lock out the electrical disconnect, block the gravitational energy of the ram, and apply a lock to the pneumatic ball valves.     (c)  Employees setting up the Verson partial revolution mechanical power presses and the Stamtec partial revolution mechanical power presses, were not adequately trained on the energy control program, in that they did not isolate the electrical energy sources and attach a lock, and they did not always use a safety block to block the gravity energy source of the ram.  When safety blocks were used, they were not always adjusted so that a gap was not left between the ram and the safety block.     (d)  Employees changing the blade on the Powermatic Vertical Band Saw, were not adequately trained on the energy control program, in that they did not isolate the electrical energy source and then attach a lock to the energy isolating device.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.147(d)(3):  Machine or equipment isolation. All energy isolating devices that are needed to control the energy to the machine or equipment shall be physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    (a)  Employees cleaned, set up, and performed maintenance on the two vertical injection molding machines, without first isolating the energy sources, such as the electrical disconnect and the pneumatic ball valves and blocking the gravitational energy of the ram.     (b)  Employees cleaned, changed tags on the dies, and set up the mechanical power presses, without first isolating the energy sources, such as the electrical disconnect and the pneumatic ball valve and blocking the gravitational energy of the ram.    (c)  Employees changed the blades on the Powermatic Vertical Saw without first isolating the electrical energy source, such as the electrical disconnect or the plug.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(4)(i):  Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees:    (a)  Authorized employees set up and performed maintenance on the two vertical injection molding machines without first affixing a lockout device to the energy isolating devices such as the electrical disconnect and the pneumatic ball valves and blocking the gravitional energy of the ram.    (b)  Authorized employees performed die changes on the mechanical power presses, without first affixing a lockout device to the energy isolating devices such as the electrical disconnect and the pneumatic ball valves and blocking the gravitional energy of the ram.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $10,780 · Current $0 Reduced

General-duty citation text

29 CFR 1910.147(c)(5)(i):  Locks, tags, chains, wedges, key blocks, adapter pins, self-locking fasteners, or other hardware shall be provided by the employer for isolating, securing or blocking of machines or equipment from energy sources:    (a)  Press operators, job setters, tool makers, and team leaders were not provided with locks and tags to attach to the energy isolating devices, prior to changing dies, or cleaning between the dies and cleaning the bolster table, on the Verson partial revolution presses (6) and Stamtec partial revolution presses (17).      (b)  Press Operators and job setters were not provided with locks and tags to attach to the energy isolating devices, prior to cleaning, setting up, and servicing the Cincinnati Milicron Vertical Injection Molding Machine #123 and the Autojectors Vertical Injection Molding Machine #124.     THE COMPANY WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD, WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 314831983, CITATION NUMBER 02, ITEM NUMBER 01, ISSUED ON SEPTEMBER 13, 2010, WITH RESPECT TO A WORKPLACE LOCATED AT 265 LIGHTNER ROAD, TIPP CITY, OHIO.

Issued

Jul 2, 2012

Abate by

Aug 1, 2012

Penalty

Initial $5,390 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):  Types of guarding. One or more methods of machine guarding shall be 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. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.:    (a)  The Autojectors Vertical Injection Molding Machine #124 was inadequately guarded, in that the light curtain was set up two feet from the side of the rotating table, therefore allowing employees to step inside the light curtain, which would automatically reset, and make adjustments to the machine.     (b)  The blade on the Powermatic Vertical Band Saw  was not properly guarded, in that there was 3 inches of exposed blade.      (c)  The powered Peerless Hacksaw was not properly guarded, in that there was 17-1/2 inches of unguarded blade.    (d)  The chuck on the Webb Machine Lathe was not guarded.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $3,080 · Current $1,500 Reduced

General-duty citation text

29 CFR 1910.215(a)(4):  Work rests. On offhand grinding machines, work rests shall be used to support the work. They shall be of rigid construction and designed to be adjustable to compensate for wheel wear. Work rests shall be kept adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent the work from being jammed between the wheel and the rest, which may cause wheel breakage. The work rest shall be securely clamped after each adjustment. The adjustment shall not be made with the wheel in motion:    (a)  There was no tool rest on the right abrasive wheel of the Dayton Pedestal Grinder and there was a gap of 2 inches between the tool rest and the abrasive wheel on the left side.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $3,080 · Current $0 Reduced

General-duty citation text

29 CFR 1910.215(b)(9):  Exposure adjustment. Safety guards of the types described in Subparagraphs (3) and (4) of this paragraph, where the operator stands in front of the opening, shall be constructed so that the peripheral protecting member can be adjusted to the constantly decreasing diameter of the wheel. The maximum angular exposure above the horizontal plane of the wheel spindle as specified in paragraphs (b)(3) and (4) of this section shall never be exceeded, and the distance between the wheel periphery and the adjustable tongue or the end of the peripheral member at the top shall never exceed one-fourth inch. (See Figures O-18, O-19, O-20, O-21, O-22, and O-23.):    (a)  There were no adjustable upper peripheral guards on the left or right side abrasive wheels on the Dayton Pedestal Grinder, leaving a gap of 2 inches between the left side abrasive wheel and the guard and a gap of 1-3/4 inches between the right side abrasive wheel and the guard.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $0 Reduced

General-duty citation text

29 CFR 1910.217(b)(9)(v):  Air counterbalance cylinders shall incorporate means to prevent failure of capability (sudden loss of pressure) in event of air supply failure:    (a)  The Stamtec partial revolution presses (17), the Verson partial revolution presses (6), the Minster Partial Revolution Press (1), the Bliss Partial Revolution Press (1), the Danly Partial Revolution Press (1), and the Heller-Sutherland Partial Revolution Press (1), all had air counterbalances, but they had only one air pressure switch.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.217(d)(9)(i):  The employer shall establish a diesetting procedure that will insure compliance with paragraph (c) of this section:    (a)  There were no die setting procedures for the Verson partial revolution presses, the Stamtec partial revolution presses, the Minster Partial Revolution Press, the Bliss Partial Revolution Press, and the Danly Partial Revolution Press.

Issued

Jul 2, 2012

Abate by

Jul 24, 2012

Penalty

Initial $5,390 · Current $2,700 Reduced

General-duty citation text

29 CFR 1910.217(d)(9)(iv):  The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press:    (a)  Employees changing ID code tags and date code tags on the dies in the Verson partial revolution pressses (6) and the Stamtec partial revolution presses (17), were not required to use safety blocks.

Issued

Jul 2, 2012

Abate by

Aug 31, 2012

Penalty

Initial $5,390 · Current $500 Reduced

General-duty citation text

29 CFR 1910.217(f)(2):  Instruction to operators. The employer shall train and instruct the operator in the safe method of work before starting work on any operation covered by this section. The employer shall insure by adequate supervision that correct operating procedures are being followed:      (a)  Employees operating the Verson partial revolution presses (6), the Stamtec partial revolution presses (17), the Minster Partial Revolution Press (1), the Bliss Partial Revolution Press (1), and the Danly Partial Revolution Press (1), and the Heller-Sutherland Partial Revolution Press (1) were not adequately trained on how their presses functioned, including the differences between full revolution and partial revolution presses, the importance of stop time measurements and how those measurements affected the placement of light curtains or palm buttons,  the purpose of the emergency stop buttons and how and when to use them,  how and when to clean the press dies, how and when to attach date tags to the dies.

Issued

Jul 2, 2012

Abate by

Aug 31, 2012

Penalty

Initial $10,780 · Current $4,000 Reduced

General-duty citation text

29 CFR 1910.147(c)(6)(i):  The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed:    (a)  The periodic inspection of the energy control procedures did not include a review between the inspector and each authorized employee, of that employees responsibilities under the energy control program, including observing the authorized employees actually performing servicing and/or maintenance activities on machines or equipment, such as, but not limited to, the Verson Mechanical Power presses, the Stamtec Mechanical Power Presses, the Milacron Vertical Injection Molding Machine #123, the Autojectors Vertical Injection Molding Machine #124, and the Powermatic Vertical Band Saw.       THE COMPANY WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD, WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 314831983, CITATION NUMBER 01, ITEM NUMBER 02, AND WAS AFFIRMED AS A FINAL ORDER ON OCTOBER 6, 2010 WITH RESPECT TO A WORKPLACE LOCATED AT 265 LIGHTNER ROAD, TIPP CITY, OHIO.    THE COMPANY WAS ALSO PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD, WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 311243448, CITATION NUMBER 01, ITEM NUMBER 03, AND WAS AFFIRMED AS A FINAL ORDER ON AUGUST 15, 2007 WITH RESPECT TO A WORKPLACE LOCATED AT 265 LIGHTNER ROAD, TIPP CITY, OHIO.

Issued

Jul 2, 2012

Abate by

Sep 14, 2012

Penalty

Initial $10,780 · Current $5,300 Reduced

General-duty citation text

29 CFR 1910.217(e)(1)(i):  It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of his power presses to ensure that all their parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment. The employer shall maintain a certification record of inspections which includes the date of inspection, the signature of the person who performed the inspection and the serial number, or other identifier, of the power press that was inspected:      (a)  There were no periodic and regular inspections of the mechanical power presses, to include checking that all their parts, auxiliary equipment, and safeguards were in a safe operating condition and adjusted to include verifying the proper placement of the light curtains and palm buttons at a safe distance from the nearest pinch point, as well as sizing safety blocks to the proper shut height.     THE COMPANY WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD, WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 311243448, CITATION NUMBER 01, ITEM NUMBER 06, AND WAS AFFIRMED AS A FINAL ORDER ON AUGUST 15, 2007, WITH RESPECT TO A WORKPLACE LOCATED AT 265 LIGHTNER ROAD, TIPP CITY, OHIO.