OSHA Inspection: A & B FOUNDRY & MACHINING LLC

Issued

May 14, 2013

Abate by

Jul 1, 2013

Penalty

Initial $3,080 · Current $1,357 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):     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 from struck-by hazards from the use of below the hook lifting devices.    Melders and Cut Off employees were exposed to a struck-by hazard by untested, unrated and unmarked below-the-hook lifting devices in conjunction with 10 and 15 ton overhead cranes and 1/2 - 2 ton jib crane hoists to lift crucibles with a crucible holder, furnace pots with a furnace pot lifting hook beam, and j-and s-hooks to lift aluminum parts onto tables, weighing approximately 25 to thousands of pounds.

Issued

May 14, 2013

Abate by

May 14, 2013

Penalty

Initial $3,080 · Current $1,357 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):     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 from a struck-by hazard from a dropped load.    In the X-Ray Room, an X-ray technician employee was exposed to a struck-by hazard from an inoperative safety latch on a hook of a Rigid two ton jib crane hoist while lifting and moving an aluminum part on a synthetic sling for x-ray.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $5,390 · Current $2,376 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):     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 from a struck-by hazard from a falling overhead load.    On or about January 30, 2013, in the Mold Area, a Mold employee was exposed to a struck-by hazard while standing underneath a suspended stacked metal box mold from a two ton jib crane hoist and two, two leg alloy steel chain slings, attached to the ends of the mold in which to look for holes in the mold and then plug them in by painting them with a resin compound.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $3,080 · Current $1,357 Reduced

General-duty citation text

29 CFR 1910.22(a)(1):     All places of employment, passageways, storerooms, and service rooms shall be kept clean and orderly and in a sanitary condition.    In the Pattern Mold Building, a pattern maker employee was exposed to a slip and fall hazard due to the excessive amount of wood dust on the floor around the table saw machine and the lack of housekeeping in the shop.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $5,390 · Current $2,376 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 shall be 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 to a ramp, stairway, or fixed ladder. The railing shall be provided with a toeboard wherever, beneath the open sides,    In the Meld Area at the Reverb Furnace Pit, a Metal Melder employee was exposed to an eight-foot fall hazard due to no midrail and toeboard at a 46-inch gap where only a chain, 39 inches in height, acting as a top rail runs across where the trough comes out of the Reverb furnace and into the pit.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $2,310 · Current $1,018 Reduced

General-duty citation text

29 CFR 1910.101(b):     "Compressed gases." The in-plant handling, storage, and utilization of all compressed gases in cylinders, portable tanks, rail tankcars, or motor vehicle cargo tanks shall be in accordance with Compressed Gas Association Pamphlet P-1-1965, which is incorporated by reference as specified in Sec. 1910.6.    In the Spectrograph Room, an Argon replacement compressed gas cylinder, approximately five feet in height, was upright against a steel storage cabinet where it could be knocked over.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $5,390 · Current $2,376 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.  In the Reverb Furnace Pit Area, a Metal Melter employee was exposed to a six-foot fall hazard without being provided personal fall protection equipment while standing on top of a furnace pot and using a long scraper tool to scrape out the remaining molten aluminum out of a furnace pot after a pour.    b.  On or about January 16, 2013, a Metal Melder employee was exposed to at least a seven-foot fall hazard without being provided personal fall protection equipment while getting off a mobile ladder stand and standing on a mold to put "hot topping" into the pour mold openings.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $3,850 · Current $1,696 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.    Periodic inspections of the Company's 56 specific and generic energy control procedures had not been conducted on at least an annual basis.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i)(A):     Each authorized employee shall receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available in the workplace, and the methods and means necessary for energy isolation and control.    In the Rough Grinding Area, a Cut Off employee who has changed the saw blade on the cut off saw on a daily basis had not received authorized employee training on the types (pneumatic and electrical) and magnitude of the energy available and the means and methods necessary for energy isolation and control.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

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.    In the Rough Grinding Area, a Cut Off employee who had changed a saw blade on the cut off saw (specifically designed and manufactured for company by PDSI) on a daily basis did not affix a lock to the 480 Volt AC electrical disconnect switchbox and pneumatic energy source.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $3,080 · Current $1,357 Reduced

General-duty citation text

29 CFR 1910.178(l)(1)(i):     The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).    a. Core Maker employee had not received any training and evaluation as specified in paragraph (l) on an electric pallet jack truck used on a daily basis to move molds on a skid.    b. Metal Melder employee had not received any training and evaluation as specified in paragraph (l) on a sit-down propane forklift used to move materials on a skid to the meld area.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $2,310 · Current $1,018 Reduced

General-duty citation text

29 CFR 1910.184(e)(1):     Sling identification. Alloy steel chain slings shall have permanently affixed durable identification stating size, grade, rated capacity, and reach.    In the Mold Area, a Mold employee was using two, two leg alloy steel chain slings for lifting a stacked square mold with one of the two leg slings missing a permanently affixed durable identification.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $3,080 · Current $1,357 Reduced

General-duty citation text

29 CFR 1910.184(i)(9)(iii):     Snags, punctures, tears or cuts;    In the X-Ray Room, an X-Ray technician was using a two foot synthetic web nylon sling which had snags, punctures, tears and a red line showing in the stitch and was not removed from use.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

General-duty citation text

29 CFR 1910.213(d)(1):     Each circular crosscut table saw shall be guarded by a hood which shall meet all the requirements of paragraph (c)(1) of this section for hoods for circular ripsaws.    In the Pattern Mold Shop Building, an operator using a Delta Unisaw 10" Table Saw Machine was exposed to an amputation hazard due to the lack of a guard over the saw blade.

Issued

May 14, 2013

Abate by

Jun 3, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.213(s)(9):     Push sticks or push blocks shall be provided at the work place in the several sizes and types suitable for the work to be done.    In the Pattern Mold Shop Building, a Pattern Maker was exposed to an amputation hazard from not using push sticks while using the Unisaw 10" Table Saw Machine to cut wood for various patterns.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

General-duty citation text

29 CFR 1910.213(h)(1):     The upper hood shall completely enclose the upper portion of the blade down to a point that will include the end of the saw arbor. The upper hood shall be constructed in such a manner and of such material that it will protect the operator from flying splinters, broken saw teeth, etc., and will deflect sawdust away from the operator. The sides of the lower exposed portion of the blade shall be guarded to the full diameter of the blade by a device that will automatically adjust itself to the thickness of the stock and remain in contact with stock being cut to give maximum protection possible for the operation being performed.    In the Pattern Mold Shop Building, the Pattern Maker was exposed to an amputation hazard while operating the Dewalt Radial Arm Saw Machine without the lower guard for the saw blade.

Issued

May 14, 2013

Abate by

Jun 17, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

General-duty citation text

29 CFR 1910.213(j)(3):     Each hand-fed jointer with a horizontal cutting head shall have an automatic guard which will cover all the section of the head on the working side of the fence or gage. The guard shall effectively keep the operator's hand from coming in contact with the revolving knives. The guard shall automatically adjust itself to cover the unused portion of the head and shall remain in contact with the material at all times.    In the Pattern Mold Shop Building, the Pattern Maker was exposed to an amputation hazard due to the guard over horizontal cutting head of the Oliver Joiner Machine would not automatically adjusting itself to cover the unused portion of the head and remain in contact with the material at all times.

Issued

May 14, 2013

Abate by

May 24, 2013

Penalty

Initial $2,310 · Current $1,018 Reduced

General-duty citation text

29 CFR 1910.303(g)(1):     Space about electric equipment. Sufficient access and working space shall be provided and maintained about all electric equipment to permit ready and safe operation and maintenance of such equipment.    On the outside wall of the Inspection Open Bay Area, an employee who turns on and off lighting circuits in an electrical panelboard for the Mold and Cut Off Area was exposed to an electrical hazard due to the lack of access space to get into the electrical panelboard due to a 55 gallon drum on top of a mobile stand parked in front of the electrical panelboard.

Issued

May 14, 2013

Abate by

May 14, 2013

Penalty

Initial $2,310 · Current $1,018 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii):     Unused openings in cabinets, boxes, and fittings shall be effectively closed.    In the Old Foundry Building, an employee was exposed to an electric shock hazard while turning on and off lighting circuits due to an open space in a 240 Volt AC electrical panelboard.

Issued

May 14, 2013

Abate by

May 24, 2013

Penalty

Initial $2,310 · Current $1,018 Reduced

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(B):     Where run through holes in walls, ceilings, or floors;    Along the outside wall next to the Open Bay Inspection Room, a Cut Off employee was exposed to an electric shock hazard while using a Burr King belt sander with a 110 Volt AC power cord running through a hole in the wall to an electrical receptacle outlet.

Issued

May 14, 2013

Abate by

May 14, 2013

Penalty

Initial $3,850 · Current $1,696 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(ii):     Flexible cords may be used only in continuous lengths without splice or tap. Hard-service cord and junior hard-service cord No. 14 and larger may be repaired if spliced so that the splice retains the insulation, outer sheath properties, and usage characteristics of the cord being spliced.    In the X-Ray Room, the 110 Volt AC flexible power cord for the two ton Rigid electric jib crane hoist motor was spliced and did not retain its insulation, outer sheath properties, and usage characteristics due to the cord being spliced.

Issued

May 14, 2013

Abate by

Jun 10, 2013

Penalty

Initial $11,550 · Current $5,090 Reduced

General-duty citation text

29 CFR 1910.157(g)(2):     The employer shall provide the education required in paragraph (g)(1) of this section upon initial employment and at least annually thereafter.    An educational program covering the principles of fire extinguisher use and the hazards involved with incipient stage fire fighting had not been provided to new employees and provided annually to all other employees.      A & B Foundry and Machining LLC was previously cited for a violation of this Occupational Safety and Health Standard, which was contained in OSHA inspection number 312945264, citation 2, item 2, issued on April 16, 2009 which became a Final Order on May 7, 2009.

Issued

May 14, 2013

Abate by

May 14, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(a)(3): Exit routes must be free and unobstructed. No materials or equipment may be placed, either permanently or temporarily, within the exit route. The exit access must not go through a room that can be locked, such as a bathroom, to reach an exit or exit discharge, nor may it lead into a dead-end corridor. Stairs or a ramp must be provided where the exit route is not substantially level.  In the Spectrograph Room, the exit door leading out of the room was partially blocked by a storage cabinet and the exit access measured only 22 inches.

Issued

May 14, 2013

Abate by

Jul 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(4)(iii):     An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.    Powered industrial truck operators in the facility had not received an evaluation of the operator performance at least once every three years.