OSHA Inspection: MELFRED MANUFACTURING COMPANY, INC.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $2100.00 · Current $1050.00 Reduced

General-duty citation text

29 CFR 1910.23(c)(1): Every open-sided floor or platform 4 feet or more above adjacent floor or ground level was not  guarded by a standard railing (or the equivalent as specified in paragraph (e)(3) of this section) on all open sides except where there is entrance toa ramp, stairway, or fixed ladder:    Instances including, but not limited to the following, fall protection was not provided:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, at the loading dock area, the employer did not ensure that appropriate fall protection was provided/used where workers were exposed to falls of over 4 feet.

Issued

2012-09-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.24(h): Standard railings were not provided on the open sides of all exposed stairways and stair platforms, handrails were not provided on at least one side of closed stairways preferably on the right side descending or stairrailings and handrails were not installed in accordance with the provisions of 1910.23:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during production activities, the employer did not ensure that the stairs leading from the General Wire area up to an upper level, were provided with a standard railing in that no midrail was provided.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $3500.00 · Current $1754.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(i): Procedures were not developed, documented and utilized for the control of potentially hazardous energy when employees are engaged in the activities covered by this section:     Instances including, but not limited to the following, energy control procedures were documented and used:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about March 23, 2012, during bandsaw blade changing activities on the Hydromech horizontal bandsaw, model number S 20, serial number 8A0207080, located in the ladder department, the employer did not ensure that machine specific lockout procedures were created and used. The unit has mulitple energy sources, including air, hydraulic, electric and gravity energy sources and appropriate energy control procedures were not documented and followed during the work.    Note: Exception: The employer need not document the required procedure for a particular machine or equipment, when all of the following elements exist: (1) The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; (2) the machine or equipment has a single energy source which can be readily identified and isolated; (3) the isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; (4) the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; (5) a single lockout device will achieve a locker-out condition; (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; (7) the servicing or maintenance does not create hazards for other employees; and (8) the employer, in utilizing this exception, has had no accidents involving the unexpected activation or reenergization of the machine or equipment during servicing or maintenance.

Issued

2012-09-19 00:00:00

Abate by

2012-10-11 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(6)(i): The employer did not 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) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, the employer did not ensure that an audit of the energy control program was performed on at least an annual basis. Deficiencies noted included, but were not limited to, failing to use energy control procedures during blade changes on bandsaws or set up work on press brakes or iron workers, not having machine specific energy control procedures developed and used while performing service/maintenance work on machinery, not using blocks for gravity energy when cleaning out between press dies, not applying locks to all energy sources prior to service/maintenance work and allowing one person to work under another person's lock during set up work on mechanical power presses.

Issued

2012-09-19 00:00:00

Penalty

Initial $3500.00 · Current $1754.00 Reduced

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    Instances including, but not limited to the following, all energy isolating devices were not located and shut off:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 1, 2012, during bandsaw blade changes on the Powermatic bandsaw, model # 7, unit # 252, located in the EAS department, the employer did not ensure that all energy isolating devices were located and operated. The employees changing blades shut off the saw, but did not shut off electrical power to it.

Issued

2012-09-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(d)(4)(i): Lockout or tagout devices were not affixed to each energy isolating device by authorized employees:    Instances including, but not limited to the following, locks were not applied to each energy isolating device for machinery:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about February 23, 2012, during bandsaw blade changing activities on the Hydromech Series III horizontal bandsaw, unit S-28A, located in the ladder department, the employer did not ensure that lock was applied to the main electrical disconnect.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $3500.00 · Current $1754.00 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. Examples of guarding methods are-barrier guards, two-hand tripping devices,electronic safety devices, etc.:    Instances including the following, machine guarding was not used where needed:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during production activities on the Wysong sheer, serial number P-15-332, located in the EAS department, the employer did not ensure that machine guarding was provided over the hold down clamps.    b) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April March 16, 2012, during production activities on the Hydromech Series III horizontal bandsaw, unit S-28A, located in the ladder department, the employer did not ensure that machine guarding was provided over the unused portion of the saw blade.     c) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about August 17, 2012, during production activities on the Powermatic bandsaw located in the EAS department, the employer did not ensure that machine guarding was provided over the unused portion of the blade.     d) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about August 17, 2012, during production activities on the horizontal sanding machine located in the EAS department, the employer did not ensure that machine guarding was provided over the nip points between the sanding belt and the wheel.

Issued

2012-09-19 00:00:00

Abate by

2012-12-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.212(a)(3)(ii): The point of operation of machines whose operation exposes an employee to injury, was not guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle:    Instances including, but not limited to the following, machine guarding was not provided over points of operation:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about May 15, 2012, during production activities at the Scotchman Ironworker machine, serial number 717OM997, located in the EAS department, the employer did not ensure that machine guarding was provided over the cutting blade area of the machinery (point of operation).    b) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about August 17, 2012, during production activities on the Bender Machine, located in the Ladder department, the employer did not ensure that machine guarding was provided over the bending mechanism where parts are loaded and then processed (point of operation).    c) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about July 12, 2012, during production activities on the Verson Press Brake, located in the EAS department, the employer did not ensure that machine guarding was provided/used to prevent entry in between the upper and lower die area (point of operation).    d) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during production activities on the Wysong sheer, serial number P-15-332, located in the EAS department, the employer did not ensure that machine guarding was provided over cutting blade (point of operation).

Issued

2012-09-19 00:00:00

Penalty

Initial $2800.00 · Current $1400.00 Reduced

General-duty citation text

29 CFR 1910.212(a)(5): Blades of fans less than seven (7) feet above the foor or working level were not properly guarded and guard openings exceeded one-half (1/2) of an inch:    Instances including, but not limited to the following, appropriate machine guarding did not exist on fans:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about March 30, 2012, the employer did not ensure that proper guarding was provided on the Dayton industrial fan model number 8C854C, located in the ladder department. The guard was badly damaged in many areas and the casing had been broken, allowing the guard to spread open greater than 1/2", making contact with the blade possible.

Issued

2012-09-19 00:00:00

Penalty

Initial $2800.00 · Current $1400.00 Reduced

General-duty citation text

29 CFR 1910.217(b)(4)(i): The pedal mechanism was not protected to prevent unintended operation from falling or moving objects or by accidental stepping onto the pedal:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the Cleveland # 2 Mechanical Power Press located in the Chop Shop, the employer did not ensure that the foot pedal used to activate the machine was provided with a cover to prevent accidental press activation.

Issued

2012-09-19 00:00:00

Abate by

2012-11-12 00:00:00

Penalty

Initial $3500.00 · Current $1754.00 Reduced

General-duty citation text

29 CFR 1910.217(c)(2)(i)(b): Guarding did not conform to the maximum permissible openings of Table O-10:    Instances including, but not limited to the following, guard openings were too large:     a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the Cleveland Press, unit # 2, located in the Chop Shop, the employer did not insure that properly applied point of operation guarding existed in that the guard openings on the top, sides and front lower section exceeded those permissible by table 0-10. Openings in the guarding were found to be at least approximately 3 1/4" by 4" in size, and was approximately 12 1/2" to the point of operation.     b) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about July 12, 2012, during parts production activities on the Rouselle mechanical power press, unit # 133, located in the Ladder Department, the employer did not insure that properly applied point of operation guarding existed in that the guard openings on the top, sides and front lower section exceeded those permissible by table 0-10. Openings in the guarding were found to be at least approximately 4 1/2" by 3 1/2" in size, and was approximately  8 1/4" to the point of operation.     c) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the L&J  mechanical power press, unit # 1, located in the Chop Shop, the employer did not insure that properly applied point of operation guarding existed in that the guard openings on the top, sides and front lower section exceeded those permissible by table 0-10. Openings in the guarding were found to be at least approximately 1 1/2" by 3 3/4" in size, and was approximately 6 3/4" to the point of operation.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.217(c)(2)(i)(d): Guards did not utilize fasteners not readily removable by operator, so as to minimize the possibility of misuse or removal of essential parts:    Instances including, but not limited to the following, guarding did not protect operators from entry into the point of operation:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the L&J press, unit # 1, located in the Chop Shop, the employer did not ensure that the barrier guard on the top half of the press was secured with fasteners that prevented it from being easily removed. The upper guard section could be removed from the press by lifting it upwards and there was a flap of plastic extending from the bottom of the upper guard down over the top of the lower guard that could be easily raised up, exposing moving parts.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.217(c)(2)(iii): A fixed barrier guard was not attached securely to the frame of the press or to the bolster plate:    Instances including, but not limited to the following, guarding did not protect operators from entry into the point of operation:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the Cleveland Press, unit # 2, located in the Chop Shop, the employer did not ensure that the barrier guard that was on the unit was fixed to prevent movement. The guard moved around in several directions easily by hand.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.217(d)(4): The hazard created by a guide post (when it is located in the immediate vicinity of the operator) when separated from its bushing by more than one-fourth inch shall be considered as a point of operation hazard and was not protected in accordance with paragraph (c) of this section:    Instances including, but not limited to the following, guarding did not protect operators from entry into the point of operation:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during parts production activities on the L&J press, unit # 1, located in the Chop Shop, the employer did not ensure that the barrier guard that was on the unit prevented entry into the guidepost area.

Issued

2012-09-19 00:00:00

Penalty

Initial $2100.00 · Current $1050.00 Reduced

General-duty citation text

29 CFR 1910.303(b)(1): Electric equipment was not free from recognized hazards that are likely to cause death or serious physical harm to employees:    Instances including, but not limited to the following, electric equipment was not free from recognized hazards:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 5, 2012, during production activities, the employer did not ensure that the power cord for the Dayton fan, located in the ladder department, had a safe electrical cord in that the outer jacket on the cord had been torn away, exposing inner wiring which was also beginning to fray.

Issued

2012-09-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(h)(7): Portable cables were operated with splices without the splices are of the permanent molded, vulcanized, or other approved type:    Instances including, but not limited to the following, electric equipment was not free from recognized hazards:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about July 12, 2012, the employer did not ensure that an appropriate splice in the power cord for an arc welding unit in the ladder department had been performed.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.217(d)(9)(iv): The employer did not provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press:    Instances including, but not limited to the following, die blocks were not used:    A) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about April 2, 2012, during die setting activities on the Cleveland mechanical power press, unit # 2, located in the chop shop, the employer did not ensure that die blocks were used while setting the dies.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.217(e)(1)(ii): Each press was not inspected and tested no less than weekly to determine the condition of the clutch/brake mechanism, antirepeat feature and single stroke mechanism:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about July 12, 2012, the employer did not ensure that presses were inspected on a weekly basis for the condition of of clutch/brake, anti-repeat or single stroke mechanisms.

Issued

2012-09-19 00:00:00

Abate by

2012-11-12 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.219(e)(3)(i): Vertical and inclined belts were not enclosed by a guard conforming to standards in paragraphs (m) and (o) of this section:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or  about July 12, 2012, during production activities on press # 133, located in the ladder department, the employer did not ensure that the drive belt was enclosed by a guard.

Issued

2012-09-19 00:00:00

Abate by

2012-09-26 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.254(d)(9)(iii): Cables with damaged insulation or exposed bare conductors were not replaced:    a) Jobsite, 390 Fountain Street, Pittsburgh, PA: On or about July 12, 2012, during welding activities in the ladder department, the employer did not ensure that the welding whip for a Pananic KF 350 arc welding unit had a whip cable that was free from damaged insulation.