OSHA Inspection: KVK FOUNDRY, INC.

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.22(a)(1):     All places of employment, passageways, storerooms or service rooms were not kept clean and orderly or in a sanitary condition:     On or about 2/01/2013, accumulations in the grinding area of aluminum metal dust, generated during grinding of cast parts with a fixed abrasive belt machine and pneumatic handheld tools, had settled on equipment surfaces, work tables, electrical conduit, and a breaker panel box.     Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.22(a)(2):     The floor of every workroom was not maintained in a clean and, so far as possible, a dry condition. Where wet processes are used, drainage shall be maintained, and false floors, platforms, mats, or other dry standing places should be provided where practicable:     On or about 2/01/2013, accumulations in the grinding area of aluminum metal dust, generated during grinding of cast parts with a fixed abrasive belt machine and pneumatic handheld tools, had settled on the floor around the perimeter of the room.     Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

Jul 15, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.132(a):     Protective equipment was not used when necessary whenever hazards capable of causing injury and impairment were encountered:    Metal Pouring Area - On or about 12/06/2012, foundry pouring employees were exposed to burns on the upper leg while transporting a ladle filled with molten aluminum metal from the furnace to the molds.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.157(g)(1):     An educational program was not provided for all employees to familiarize them with the general principles of fire extinguisher use and the hazards involved with incipient stage firefighting:     On or about 12/06/2012, employees in the grinding area were expected by the employer to use a class D fire extinguisher in the event of a fire involving combustible metals. Employees had not been provided with an educational program to familiarize them with the general principles of fire extinguisher use and the hazards involved with incipient stage firefighting.     Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.(19)(c).

Issued

May 8, 2013

Abate by

Jul 1, 2013

Penalty

Initial $1,200 · Current $600 Reduced

General-duty citation text

29 CFR 1910.179(j)(2):     The following items were not be inspected for defects at intervals as defined in paragraph (j)(1)(ii) of this section or as specifically indicated, including observation during operation for any defects which might appear between regular inspections:    On or about 12/06/2012, the employer had not completed frequent (monthly at minimum) inspections of its overhead Yale 2-ton cranes.     Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

Jul 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.179(j)(3):     A complete periodic inspection of crane(s) had not been conducted in the past 12 months:    On or about 12/06/2012, the employer had not completed a periodic (yearly at minimum) inspection of its overhead Yale 2-ton cranes.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

Jul 1, 2013

Penalty

Initial $1,600 · Current $800 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:    On or about 12/06/2012, a side guard for the abrasive belt grinding machine was not in place, exposing the employee operator to an in-going nip point between the abrasive belt and the spinning wheel.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.213(i)(1):     Non-working portion(s) of the blade of bandsaw(s) were not enclosed or guarded:    On or about 2/01/2013, an employee using the vertical band saw in the grinding area was exposed to cuts from the unused and unguarded portion of the blade above the material to be cut.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

Jul 1, 2013

Penalty

Initial $2,400 · Current $1,200 Reduced

General-duty citation text

29 CFR 1910.243(c)(1):     Abrasive wheel(s) were used on portable grinder(s) which were not provided with safety guard(s) meeting the requirements specified in 29 CFR 1910.243(c)(1) through (c)(4):    On or about 2/01/2013, employees in the grinding area were using pneumatic hand grinders without guards.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.305(b)(2):     Each outlet box in completed installations did not have a cover, faceplate, or fixture canopy:    On or about 2/01/2013, employees in the grinding area were exposed to electrical shock hazards from an outlet box with an improperly affixed faceplate.    Abatement certification is required of the item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

Jul 15, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.307(c):     Equipment, wiring methods, and installations of equipment in hazardous (classified) locations were not intrinsically safe, approved for the hazardous (classified) location, or safe for the hazardous (classified) location:    On or about 2/01/2013, employees in the grinding area were using pneumatic hand tools to grind cast aluminum parts, generating aluminum dust, a Class II Group E combustible dust. General purpose wiring, breaker panel boxes, receptacles, overhead lights, and electric motors were not dust-tight or ignition proof and approved for Class II Division 1 locations.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $1,600 · Current $800 Reduced

General-duty citation text

29 CFR 1910.334(a)(2)(i):     Portable cord and plug connected equipment and flexible cord sets (extension cords) were not visually inspected before use on any shift for external defects (such as loose parts, deformed and missing pins, or damage to outer jacket or insulation) and for evidence of possible internal damage (such as pinched or crushed outer jacket):     (a) On or about 2/01/2013, employees in the grinding area were exposed to electrical shock hazards from a portable fan with a damaged flexible cord.     (b) On or about 2/01/2013, employees in the grinding area were exposed to electrical shock hazards from a wall clock with a damaged flexible cord.     Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $2,000 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.1200(h)(1):     Employees were not provided effective information and training on hazardous chemicals in their work area at the time of their initial assignment and whenever a new hazard that the employees had not been previously trained about was introduced into their work area:    On or about 12/6/2012, employees in the grinding room were not informed of or trained on the hazards associated with the combustible aluminum dust they create while grinding cast aluminum parts with portable and fixed grinding tools.    Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).

Issued

May 8, 2013

Abate by

May 8, 2013

Penalty

Initial $4,000 · Current $2,000 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 1910.95(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 or about 12/6/2012, the employer failed to maintain a continuing and effective hearing conservation program.     (a) Employee number one in the grinding room was exposed to continuous noise at 183.3% of the permissible daily noise exposure (8 hour time weighted average sound level of 90 dBA) or an equivalent sound level of approximately 95.9 dBA during the 386 minute sampling period on 2/1/2013; exposure calculations include a zero increment for the 94 minutes not sampled.     (b) Employee number two in the grinding room was exposed to continuous noise at 288.1% of the permissible daily noise exposure (8 hour time weighted average sound level of 90 dBA) or an equivalent sound level of approximately 98.7 dBA during the 412 minute sampling period on 2/1/2013; exposure calculations include a zero increment for the 68 minutes not sampled.     There is no abatement certification or documentation required for this item.    KVK Foundry, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.95(c)(1), which was contained in OSHA inspection number 312725534, citation number one, item number one and was affirmed as a final order on 07/07/2009, with respect to a workplace located at 302 Vine St, Millington, IL 60537.

Issued

May 8, 2013

Abate by

May 8, 2013

Penalty

Initial $3,200 · Current $1,600 Reduced

General-duty citation text

29 CFR 1910.134(e)(1):     The employer did not provide a medical evaluation to determine the employees ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:     On or about 12/6/2012, medical evaluations had not been provided to all employees in the grinding room who are required to wear respirators when grinding aluminum castings.     There is no abatement certification or documentation required for this item.     KVK Foundry, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.134(e)(1), which was contained in OSHA inspection number 312725534, citation number one, item number three (b) and was affirmed as a final order on 07/07/2009, with respect to a workplace located at 302 Vine St, Millington, IL 60537.

Issued

May 8, 2013

Abate by

Jun 4, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(f)(2):   The employer did not ensure that employee(s) using a tight-fitting facepiece respirator were fit tested prior to initial use of the respirator, whenever a different respirator facepiece was used, and at least annually thereafter:   (a) On or about 12/6/2012, an employee in the grinding room wearing a tight fitting respirator, the 3M Particulate Respirator N95 model 8511 with an exhalation valve, had not been fit tested for the respirator prior to initial use.   (b) On or about 12/6/2012, an employee in the grinding room wearing a tight fitting respirator, the 3M Particulate Respirator N95 model 8511 with an exhalation valve, had not been fit tested annually.   Abatement documentation is required for this item in accordance with the requirements of 29 CFR 1903.19(d).   KVK Foundry, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.134(f)(2), which was contained in OSHA inspection number 312725534, citation number one, item number three (c) and was affirmed as a final order on 07/07/2009, with respect to a workplace located at 302 Vine St, Millington, IL 60537.

Issued

May 8, 2013

Abate by

May 20, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.145(c)(3):   Safety instruction sign(s) were not used where there was a need for general instructions and suggestions relative to safety measure(s):  On or about 12/6/2012, the employer did not post a sign in, around, and/or near the grinding room which instructs that combustible aluminum dust must not be allowed to accumulate.  Abatement certification is required of this item in accordance with the requirements of 29 CFR 1903.19(c).