OSHA Inspection: CLASSIC COIL COMPANY, INC.

Issued

Sep 18, 2012

Abate by

Jan 31, 2013

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):  Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that, employees were exposed to combustible dust fire and/or explosion hazards from plastic dust arising from grinding and cutting operations:   Liquid Molding Room:  On, or about, May 1, 2012, employees used a band saw and two circular grinders to remove excess material from molded plastic parts of coils.  The resulting dust was combustible.  The dust was captured by a ventilation system that included a dust collector manufactured by Jones Metal Products Company and a series of plastic ducts.  A.  The dust collector which collected combustible dusts was located indoors near the coil assembly fnishing area.  B.  The dust collection system (i.e., the dust collector, collector ducts and associated components) which collected combustible dusts was not equipped with the measures/devices needed for fire/explosiion prevention, suppression, venting and/or isolation, to prevent or limit the spread of a combustible dust fire/explosion into the general work area.  C.  The ducts collecting and transporting combustible dust to the collector were made of flexible plastic, which is combustible and can carry a static charge (i.e., potential ignition).  D.  Exhaust air for the dust collector was recycled back into the work area such that a fire/explosion in the collector could spread inside the building.

Issued

Sep 18, 2012

Penalty

Initial $1,785 · Current $893 Reduced

General-duty citation text

29 CFR 1910.132(d)(1):  The employer did not assess the workplace to determine if hazards are present, or are likely to be present, which necessitated the use of personal protective equipment:     Company:  The employer had not conducted and documented a Personal Protective Equipment Hazard Assessment to determine what personal protective equipment was needed for various job tasks in the facility.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.133(a)(3):  The employer did not ensure that each affected employee who wore prescription lenses while engaged in operations that involve eye hazards wore eye protection that incorporated the prescription in its design, or wore eye protection that can be worn over the prescription lenses without disturbing the proper position of the prescription lenses or the protective lenses:    A.  Molding Room:  An employee was operating Press #7, a Wabash hydraulic transfer press, and using compressed air to clean mold while wearing regular, non-safety, prescription glasses without side shields.    B.  Paper Layer:  An employee operated the Manual Winding Machine No. 107 while wearing regular, non-safety glasses.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $2,800 · Current $1,400 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 were engaged in activities covered by this section:    Company:  The lockout program did not address procedures to be utilized when employees had to access hazardous areas of machines to perform set-up operations.  Employees changed timing gears on the Manual Winding Machine No. 107 without locking the machine out.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.212(a)(1):  Machine guarding was not provided to protect operator(s) and other employees from hazard(s) created by pinch points and rotating parts:    A.  Molding Room:      1.  The Newbury #3 Vertical Injection Molding Machine was not provided with safeguarding for the knockout plate pinch point.  Also, the company did not implement a periodic inspection program to ensure that all safeguards were in proper working order.  The stop plate for the mechanical stop did not work properly.      2.  The Newbury #2 Vertical Injection Molding Machine was not provided with safeguarding for the knockout plate pinch point.        3.  The Newbury #14 Vertical Injection Molding Machine was not provided with safeguarding for the knockout plate pinch point.    B.  Paper Layer:  Manual Winding Machine No. 107 was not provided with an emergency stop device such as, but not limited to, an emergency stop trip wire or bar that was accessible from all areas of the operators work station and a proper emergency stop button.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.212(a)(3)(ii):  Point(s) of operation of machinery were not guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s):    Molding Room:      A.  Denison Multipress:  The two hand levers were not provided with an anti-tie down device to require that both levers be released in between each press stroke.    B.  Press #9, Gluco Transfer Press:  The two hand toggle switches were not protected against unintended operation and were not provided with an anti-tie down device to require both switches be released in between each press stroke.    C.  Press #13, Gluco Transfer Press:  The two hand toggle switches were not protected against unintended operation and were not provided with an anti-tie down device to require both switches be released in between each press stroke.    D.  Press #6, Hull Model T-140 Transfer Press:  The right run button could be released during the closing portion of the press cycle and the press would continue through the stroke.      E.  Press #10, Fujiwa Transfer Encapsulation Press Model TEP-50-30:  The run buttons could be released near the end of the press stroke and the press would continue through the stroke.  Both the point of operation and the rubber feed area created a pinch point.      F.  Newbury #3 Vertical Injection Molding Machine:  Guarding was not provided on the sides of the machine to prevent access to the point of operation.      G.  Newbury #2 Vertical Injection Molding Machine:  Guarding was not provided on the sides of the machine to prevent access to the point of operation.      H.  Newbury #4 Vertical Injection Molding Machine:  Guarding was not provided on the sides of the press to prevent access to the point of operation.     I.  Newbury #14 Vertical Injection Molding Machine:  Guarding was not provided on the sides of the press to prevent access to the point of operation.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.217(c)(2)(i)(a):  Point of operation guard(s) on mechanical power press(es) did not prevent entry of hands or fingers into the point of operation by reaching through, over, under or around the guard(s):    Assembly Department:  Amp-O-Lectric full revolution mechanical power presse Serial Number 108558 was provided with a hinged barrier guard that could be reached around.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(c)(2)(i)(b):  Point of operation guard(s) on mechanical power press(es) did not conform to the maximum permissible opening(s) specified in Table O-10:    Assembly Department:  The following Amp-O-Lectric full revolution mechanical power presses were provided with inadequate barrier guards in that openings in the guards exceeded the maximum permitted in Table O-10 of the standard:    A.  Amp-O-Lectric serial number 108563.  B.  Amp-O-Lectric serial number 108558.  C.  Amp-O-Lectric serial number 33990.  D.  Perkins.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(c)(2)(i)(d):  Point of operation guard(s) on mechanical power press(es) did not utilized fasteners not readily removable by the operator, so as to create minimize the possibility of misuse or removal of essential parts:    Assembly:  The barrier guard provided on the Perkins full revolution mechanical power press was fastened in place by two hex bolts that could be easily removed by hand.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $2,800 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.217(e)(1)(i):  A program of periodic and regular inspections of mechanical power press(es) was not established and followed to ensure that all parts, auxiliary equipment and safeguards were in a safe operating condition and adjustment:    Company:  Full revolution mechanical power presses were used in assembly areas of the plant to crimp connectors onto coil assemblies.  The company had not developed and implemented a program of documented periodic inspections to determine the overall condition of each press.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.217(e)(1)(ii):  Mechanical power press(es) were not inspected and tested at least weekly to determine the condition of the single stroke mechanism.  Also, records of inspections and the maintenance work performed on the clutch/brake mechanism, anti repeat feature, and/or single stroke mechanism of mechanical power press(es) were not maintained:    Assembly:  Amp-O-Lectric full revolution mechanical power presses were not subject to a weekly inspection to determine the condition of the single stroke mechanism.  Also, weekly inspection records conducted on the Perkins mechanical power press did not adequately determine the condition of the single stroke mechanisms and the records were not maintained because they were erased after they were completed.

Issued

Sep 18, 2012

Penalty

Initial $1,785 · Current $893 Reduced

General-duty citation text

29 CFR 1910.219(f)(1):  Gear(s) were not guarded by a complete enclosure or by one of the methods specified in 29 CFR 1910.219(f)(1)(ii) and (f)(1)(iii):    Respool Area:  Drive gears located on the left side of Manual Winding Machine No. 107 were not provided with a guard.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.303(b)(2):  Listed or labeled electrical equipment was not used or installed in accordance with instructions included in the listing or labeling:    In the following locations, electrical equipment was not suitable for the manner in which it was used:    Electric griddles designed for Household Use were used to pre-heat parts prior to molding:    A.  Liquid Molding Room:      1.  A Rival griddle designed for household use was used to pre-heat parts prior to molding.    2.  The Baldor motor provided on disk sander used to de-gate epoxy coil assemblies was not designed for use where combustible dust was generated.  It was provided with an open motor instead of an enclosed motor.    3.  A knock-out box that contained the electric power entrance into the Jones Metal Products Model 2500 dust collector was not sealed to prevent the entry of combustible dust.    4.  The Dayton Model 3VE20 Wet/Dry vacuum used to clean fugitive combustible dust from the work area was not designed for use where combustible dust was generated.  It had an open, spark producing motor and non-grounded attachments.    B.  Mold Room:  A Presto griddle designed for household use was used to pre-heat parts prior to molding.

Issued

Sep 18, 2012

Penalty

Initial $1,785 · Current $893 Reduced

General-duty citation text

29 CFR 1910.303(g)(1)(i)(A):  For electric equipment operating at 600 volts, nominal, or less to ground, and likely to require examination, adjustment, servicing, or maintenance while energized, the depth of the working space in the direction of access to live parts (as measured from the live parts where they were exposed or from the enclosure front or opening whwere they were enclosed) was less than indicated in Table S-1 of Subpart S of Part 1910:    Main Electrical Room:  The vacuum pump for the Liquid Molding Room varnish line was installed on the floor in the working space of Panel B, a GE wall mounted panel board.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(g)(1)(i)(B):  For electric equipment operating at 600 volts, nominal, or less to ground, and likely to require examination, adjustment, servicing, or maintenance while energized, the width of the working space in front of electrical equipment was less than the width of the equipment or 762 mm (30 inches), whichever was greater and/or the working space did not permit at least a 90-degree opening of equipment doors or hinged panels:    A.  Front Corner of Plant, near Office Entrance:  Panel B, a Siemens wall mounted panelboard, was only provided with 24 inches of working space width due to the installation of a transformer on the right side and a file cabinet on the left side.    B.  Molding Room:  The door on the main control panel for Newbury 125, a vertical injection molding machine, could not be opened at least 90 degrees due to the close proximity of the machine to the front of the panel.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(g)(1)(i)(C):  Other electrical equipment associated with the electrical installation and located above or below electrical equipment extended more than 153 mm (6 inches) beyond the front of the electrical equipment:    A.  Main Electrical Room:  A Siemens transformer was located in the working space for the GE subpanel installed to the right of Panel A.      B. Front corner of Plant, near Office Entrance:  A Siemens transformer, T-2, was located in the working space for the GE subpanel, C-2.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(g)(1)(ii):  The required working space about electric equipment rated 600 volts, nominal, or less to ground, was used for storage:    Main Electrical Room:  A box and a machine component had been stored on the floor in front of Panel B, a GE wall mounted panelboard.

Issued

Sep 18, 2012

Penalty

Initial $1,785 · Current $893 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv): Flexible cords and/ or cables were used for purposes prohibited by paragraphs (A) through (F) of 29 CFR 1910.305(g)(1)(iv):    A.  Liquid Molding Room:           1.  An Air King box fan used to cool molded parts was energized through an extension cord.       2.  A radio was energized by a flexible cord that was run through a hole in the wall.    B.  Main Electrical Room:  The condensate tank discharge pump was energized through an orange and black extension cord.

Issued

Sep 18, 2012

Abate by

Oct 31, 2012

Penalty

Initial $3,500 · Current $1,750 Reduced

General-duty citation text

29 CFR 1910.333(a)(2):  Where exposed live parts were not deenergized (i.e., for reasons of increased or additional hazards or infeasibility), other safety-related work practices were not used to protect employees who could be exposed to the electrical hazards involved:    Quality Control:  The company had not developed and implemented safe work procedures for high voltage testing stations.  Surge and Hi-Pot testing up to 3,000 volts was conducted on coil assemblies in plexiglass fixtures.      1.  Live parts were exposed on the fixtures during the testing operations.  Interlocked covers, protective barriers and/or personal protective equipment was not provided.    2.  Employees had to reach over test fixtures to operate test instruments.    3.  Probes and leads were not routinely tested to ensure that they were still adequately insulated.    4.  A kill switch or other remote means to de-energize power to the test equipment was not provided.

Issued

Sep 18, 2012

Penalty

Initial $140 · Current $70 Reduced

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):    Winding:  The belt drive on the re-spooling machine was not provided with a guard on the inside face.    The company was previously cited for a violation of this occupational safety and health standard on May 23, 2007, which was contained in OSHA Inspection Number 310184700, Citation Number 1, Item Number 9b and was affirmed as a Final Order on October 4, 2007, with respect to a workplace located at Bristol, Connecticut.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(2)(iii):  Flexible cords and cables were not connected to devices and fittings so that strain relief was provided that would prevent pull from being directly transmitted to joints or terminal screws:    Liquid Molding Room:  Strain relief was not provided for the DoAll Vertical band saw power cord.

Issued

Sep 18, 2012

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.334(a)(2)(ii):  When there was a defect or evidence of damage that could expose an employee to injury, the defective or damaged item was not removed from service until the repairs and tests necessary to render the electric equipment safe had been made:    Molding Room:    The power cord provided on the Therm-All heater located at Press #7, a Wabash transfer press, was damaged, exposing the inner, coated conductors.