OSHA Inspection: GREAT WESTERN PRODUCTS COMPANY, LLC

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $4,900 · Current $1,960 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:     Employees required to bypass guards on machines in the production room were exposed to amputation hazards and hazardous energy:     a. The employer did not enforce the use of lockout procedures when jams in the 12-Ounce popcorn packaging machine were corrected by the operators.     b. The employer did not enforce the use of lockout procedures when jams in the Pouchmaster popcorn packaging machine were corrected by the operators.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d):   The established procedure for the application of energy control (the lockout or tagout procedures) did not cover the actions listed in and was not done in sequence as required by 29 CFR 1910.147(d)(1)-(6):  Employees were exposed to machine hazards associated with moving machine parts while they corrected jams that occurred in popcorn packaging machines:  a. The employer failed to implement energy control application steps while correcting jams in the 12-Ounce popcorn packaging machine as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements].  As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.  b. The employer failed to implement energy control application steps while correcting jams in the Pouchmaster popcorn packaging machine as the machine was not shut down or turned off to perform the servicing work [per the 1910.147(d)(2) requirements].  As a result, the remaining applicable energy control elements, involving machine isolation [(d)(3)], LOTO device application [(d)(4)], dissipation of residual energy [(d)(5)(i)], and verification of isolation [(d)(6)], were not implemented to protect employees from machine servicing hazards.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $3,500 · Current $1,400 Reduced

General-duty citation text

29 CFR 1910.178(a)(4):     Modifications and additions which affect capacity and safe operation of powered industrial truck were performed by the employer without the manufacturer's prior written approval:    Maintenance employees were exposed to injuries while using a shop-made work platform designed to attach to the forks of forktrucks, affecting the trucks capacity and operation, and the employer did not obtain the manufacturers prior written approval before using the attachment.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(a)(5):     The powered industrial truck was equipped with front-end attachments other than factory installed attachments, however the employer did not request that the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered:    Maintenance employees were exposed to injuries while using a shop-made work platform designed to attach to the forks of forktrucks, affecting the trucks capacity and operation, and the employer did not mark forktruck(s) with the appropriate information before using the attachment.

Issued

Jun 28, 2013

Penalty

Initial $3,500 · Current $0 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:    Employees performing maintenance tasks such as, but not limited to, changing light bulb and lighting gas heaters located near the facility ceiling were exposed to falling from a work platform placed onto the tines of a forklift because the work platform did not have a complete midrail.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $4,900 · Current $1,960 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:     Employees working in the production room were exposed to amputation hazards:     a. Rollers and pouch holding mechanisms used to advance and fill popcorn bags on the 12-Once packaging machine created both nip points and pinch points and were not guarded.     b. Rollers and pouch holding mechanisms used to advance and fill popcorn bags on the Pouchmaster packaging machine created both nip points and pinch points and were not adequately guarded.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

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):  Employees working in the production room were exposed to amputation hazards:  a. The cutting blade used to separate popcorn bags on the 12-Once packaging machine was not guarded.  b. The cutting blade used to separate popcorn bags on the Pouchmaster packaging machine was not effectively guarded.

Issued

Jun 28, 2013

Penalty

Initial $2,800 · Current $1,120 Reduced

General-duty citation text

29 CFR 1910.304(f)(1)(iv):     Overcurrent devices for circuits rated 600 volts, nominal, or less, were not readily accessible to each employee or authorized building management personnel:    Employees working in and near the Shop were exposed to electrical hazards:    a. A 480 volt electrical panel near the shop entrance was blocked by unused equipment.    b. A 208 volt electrical panel near the shop entrance was blocked by unused equipment.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $4,900 · Current $1,960 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii):     Unused openings in boxes, cabinets, or fittings were not effectively closed:    Employees were exposed to electrical hazards because a breaker switch slot was open in an electrical panel near the shop entrance and a covering had been installed to prevent accidental contact with live conductors.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(2)(i):     Each outlet box in completed installations did not have a cover, faceplate, or fixture canopy:    Employees working in the Shop were exposed to electrical hazards:      a. An electrical outlet used to power the conveyor belt to the Fischbein Company corn bagger in the production room was missing a front cover.    b. The conveyor belt speed control unit to the Fischbein Company corn bagger in the production room was not closed and live conductors were present.    c. A 110 volt outlet box in the Shop used to power a refrigerator, coffee maker, and microwave was missing the front cover.    d. A 208 volt junction box feeding power to another outlet was missing the front cover and live conductors were exposed.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $2,100 · Current $840 Reduced

General-duty citation text

29 CFR 1910.305(g)(2)(iii):     Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws:    Employees were exposed to electrical hazards:    a. Conduit to an electric motor that powered the salt mixer in the salt mixing room was broken and pulled away creating stress on the flexible cords.    b. The outer insulation was broken and pulled away from flexible cords at the rear of the Cousins Packaging corn wrapper in the production room and no strain relief was provided to those flexible cords.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $9,800 · Current $3,920 Reduced

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 requirement of this standard were being followed:    Employees required to utilize lockout procedures were exposed to amputation hazards and hazardous energy because the employer did not conduct periodic inspections with each authorized employee:    a. Operators required to unjam the 12-ounce line were never party to a periodic lockout inspection.    b. Operators required to unjam the Pouchmaster line were never party to a periodic lockout inspection.    THE GREAT WESTERN PRODUCTS COMPANY, LLC WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD 29 CFR 1910.147(c)(6)(i) WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 312892532, CITATION NUMBER 1, ITEM NUMBER 2c, AND WAS AFFIRMED AS A FINAL ORDER ON JUNE 22, 2010, WITH RESPECT TO A WORKPLACE LOCATED AT 2047 E 1350 NORTH ROAD, ASSUMPTION, IL 62510.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $9,800 · Current $3,920 Reduced

General-duty citation text

29 CFR 1910.147(c)(7)(i):     The employer did not provide adequate training to ensure that employees acquired the knowledge and skills required for the safe application, usage and removal of energy control devices:    Employees required to perform service and maintenance on machines throughout the facility were exposed to amputation hazards and hazardous energy because they had not received training that described the equipment to be used in specific applications, areas to attach the lockout devices, source(s) and type(s) of hazardous energy specific to different machines, nor identify authorized user responsibilities.    THE GREAT WESTERN PRODUCTS COMPANY, LLC WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD 29 CFR 1910.147(c)(7)(i) WHICH WAS CONTAINED IN OSHA INSPECTION NUMBER 312892532, CITATION NUMBER 1, ITEM NUMBER 2d, AND WAS AFFIRMED AS A FINAL ORDER ON JUNE 22, 2010, WITH RESPECT TO A WORKPLACE LOCATED AT 2047 E 1350 NORTH ROAD, ASSUMPTION, IL 62510.

Issued

Jun 28, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.178(l)(6):     The employer did not certify that each operator has been trained and evaluated as required by this paragraph (l):    Employees working in an area where forktrucks were operated were exposed to struck-by hazards because the employer did not certify that the forktruck operators had received training and evaluation.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

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:  Employees working in the Production Room at the Pouchmaster line were exposed to electrical hazards because a relocatable power tap was used to power the accumulation table and tape machines.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(8)(i):   Electric equipment was not firmly secured to the surface on which it was mounted:  Employees were exposed to electrical hazards because the Fischbein Company corn bagger control panel in the production room was lying on the floor and hanging by the flexible cord that provided power.

Issued

Jun 28, 2013

Abate by

Jul 25, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(1)(iv)(A):   Flexible cords and/or cables were used as a substitute for the fixed wiring of a structure:  Employees were exposed to fire and electrical hazards:  a. A fan mounted to a wall in the Production Room was plugged into a flexible cord in lieu of fixed wiring.  b. The Fischbein Company corn baggers control panel located in the production room utilized flexible cord in lieu of fixed wiring.