OSHA Inspection: LONE STAR REEL CORPORATION

Issued

2013-08-19 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $4900.00 · Current $7000.00

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 29 CFR 1910.147:       The employer does not ensure that procedures are developed, documented and utilized for the control of potentially hazardous energy when employees service and maintain machines and equipment.  This violation was discovered on March 04, 2013, in the manufacturing and assembly areas; where the employer did not develop, document and utilize procedures for the control of potentially hazardous energy when employees serviced and maintained the following machines and equipment:            a. Tyler Manufacturing power press located in the production / assembly areas.         b. Stafast power press located in the production / assembly areas.

Issued

2013-08-12 00:00:00

Abate by

2013-10-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer does not furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or likely to cause death or serious physical harm to his employees in that employees were exposed to fire, deflagration, and explosion hazards:    This violation was observed on February 12, 2013,  throughout the manufacturing facility; where the employer, by using the following dust collectors inside of the building without explosion protection systems, such as explosion venting or explosion suppresion systems, exposed employees to fire, deflagration and explosion hazards:      a. Dust collection system servicing CNC machine number one (1).      b. Dust collection system servicing CNC machine number two (2).      c. Dust collection system servicing CNC machine number three (3).      d. Dust collection system servicing CNC machine number four (4)    e. Dust collection system servicing CNC machine number five (5).

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

29 CFR 1910.22(a)(1): All places of employment, passageways, storerooms, and service rooms were not kept clean and orderly and in a sanitary condition:    The employer does not ensure that equipment , walls and ledges are kept free from hazardous accumulations of combustible dust, exposing employees to the hazards of fire, deflagration and explosion.  This violation was observed on February 12, 2013, located throughout the manufacturing facility; where saw dust had accumulated on equipment, walls, and ledges.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

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:  The employer does not ensure that workroom floors are kept free of hazardous accumulations of combustible dust, exposing employees to the hazards of fire, deflagration, and explosion.  This violation was observed on February 12, 2013, throughout the manufacturing facility; where saw dust had accumulated on the workroom floors.

Issued

2013-08-12 00:00:00

Abate by

2013-09-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

29 CFR 1910.147(c)(4)(ii): The energy control procedures did not clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, 29 CFR 1910.147(c)(4)(ii)(A), (c)(4)(ii)(B), (c)(4)(ii)(C) and (c)(4)(ii)(D):    The employer does not ensure that the energy control procedures clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance including, but not limited to, having a specific statement of the intended use of the procedure; specific procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy; specific procedural steps for the placement, removal and transfer of lockout devices or tagout devices and the responsibility for them; and specific requirements for testing a machine or equipment to determine and verify the effectiveness of lockout devices, tagout devices, and other energy control measures.  This violation was discovered on March 4, 2013 for the following machines and equipment:    a.  T-Nut Machine  b.  Crouch Sander #1  c.  Crouch Sander #2  d.  CNC 1  e.  CNC 2  f.   CNC 3  g.  CNC 4  h.  Torit Dust Cyclone for CNC 1  i.  Torit Dust Cyclone CNC 3 East Wall  j.  Dustek Dust Collection CNC Department  k.  Tube Punch  l.  Crow Machine & Dust Collector in CNC Area  m.  Conveyor Lines  n.  KUFO Dust Collector for Belt Sander

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not training to ensure that the purpose and function of the energy control program were understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls were acquired by employees:   The employer does not provide training to ensure that the purpose and function of the energy control program are understood by employees, and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees. This violation was discovered on March 04, 2013, located throughout the manufacturing and assembly areas; where employees serviced and maintained machines and equipment, but the employer did not ensure that the employees understood the purpose and function of the energy control program, and that they had acquired the knowledge and skills necessary for the safe application, usage, and removal of the energy controls.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

29 CFR 1910.176(b): Materials were not stored in a stable or secure manner:       The employer does not ensure that materials are stored in a stable and or secure manner.  This violation was discovered on February 12, 2013, in the manufacturing and warehousing areas; where industrial steel storage racks that were used store materials were not anchored to the floor.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

29 CFR 1910.178(c)(2)(vi)(a): Approved power operated industrial trucks designated as EX were not used in atmospheres in which combustible dust was or may be in suspension continuously, intermittently, or periodically under normal operating conditions, in quantities sufficient to produce explosive or ignitable mixtures, or where mechanical failure or abnormal operations of machinery or equipment might cause such mixtures to be produced:       The employer does not ensure only approved power operated industrial trucks designated as EX are used in atmospheres in which combustible dust is present.  This violation was observed on February 12, 2013, throughout the facility, where employee operated powered industrial trucks in areas with combustible dust that were not designated as EX:       a. Employees used a Mitsubishi FG30N-LP in areas that contained combustible dust;     b. Employees used a Mitsubishi FG25N-LP in areas that contained combustible dust;       c. Employees used a Mitsubishi FG25K-LP in areas that contained combustible dust.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $3500.00 · Current $1750.00 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:     The employer does not ensure that one or more methods of machine guarding are provided to protect employees from the hazards such as those created by ingoing nip points.  This violation was observed on February 12, 2013, in the assembly areas; where employees, who used a Roach conveyor line, model no.: 450B0S, were not protected from ingoing nip points:     a. Un-guarded pinch points located between the bearing ends of the head pulley, roller assembly on the number one (1) Roach Conveyor.    b. Un-guarded pinch points located between the bearing ends of the head pulley, roller assembly on the number two (2) Roach Conveyor.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $3500.00 · Current $1750.00 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in cabinets, boxes, and fittings were not effectively closed:         The employer does not ensure that unused openings in cabinets, boxes and fittings are effectively closed.  This violation was observed on February 12, 2013, in the stave cutting area; where employees were exposed to electrical hazards while working in areas where unused openings in cabinets, boxes and fittings were not effectively closed, one (1) 110 volt electrical outlet.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.305(b)(2)(i):  Each pull boxes, junction boxes, and fittings in completed installations did not have a cover, face plate, or fixture canopy:      The employer does not ensure that each pull boxes, junction boxes and fittings in completed installation have a cover, face plate or fixture canopy.  This violation was discovered on February 12, 2013, in the chipping area; where employees are exposed to the live electrical conductors, a 440VAC motor controller controlling electrical power to the Chipper machine that did not have the cover, face plate or fixture canopy secured.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $4900.00 · Current $2450.00 Reduced

General-duty citation text

29 CFR 1910.307(c)(2)(i):  Equipment in hazardous locations was not approved for the class of location, due to the presence of combustible dust:          The employer does not ensure that equipment located in hazardous locations are approved for the class of location, due to the presence of combustible dust.  This violation was discovered on February 12, 2013, in the manufacturing facility; where the employer used electrical equipment that was not approved for use in areas where there was combustible dust:           a. At CNC Machine number one (1), a Square D 220 volt electrical disconnect, supplying power to a Multi Cam power distribution panel, Model No. MC416SF31385, providing electrical power to the CNC control pad;     b. At CNC Machine number two (2), a Square D 220 volt electrical disconnect, supplying power to a Multi Cam power distribution panel, Model No. MC416SF31385, providing electrical power to the CNC control pad;       c. At CNC Machine number three (3), a Square D 220 volt electrical disconnect, supplying power to a Multi Cam power distribution panel, Model No. MC416SF31385, providing electrical power to the CNC control pad;     d. At CNC Machine number four (4), a Square D 220 volt electrical disconnect, supplying power to a Multi Cam power distribution panel, Model No. MC416SF31385, providing electrical power to the CNC control pad;       e. At CNC Machine number four (4), a Square D 220 volt electrical disconnect, supplying power to a Multi Cam power distribution panel, Model No. MC416SF31385, providing electrical power to the CNC control pad.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.307(d): All conduits were not threaded and made wrench-tight:         The employer does not ensure that all conduits are threaded and made wrench-tight.  This violation was discovered on February 12, 2013, throughout the facility; where the employer used conduits that were not threaded and made wrench-tight in areas where combustible dust was located:       a. One (1) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to CNC machine number one (1) ; one-half (1/2) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to a Grizzly Model No. G0601 dust collection system;    b. One (1) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to CNC machine number two (2); one-half (1/2) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to a Grizzly Model No. G0601 dust collection system;   c. One (1) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to CNC machine number three (3); one-half (1/2) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to a Grizzly Model No. G0601 dust collection system;     d. One (1) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to CNC machine number four (4); one-half (1/2) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to a Grizzly Model No. G0601 dust collection system;   e. One (1) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to CNC machine number five (5); one-half (1/2) inch electrical magnetic tubing that was connected to a Square D electrical disconnect that provided electrical power to a Grizzly Model No. G0601 dust collection system.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $56000.00 · Current $7000.00 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 were engaged in activities covered by 29 CFR 1910.147:       The employer does not ensure that procedures are developed, documented and utilized for the control of potentially hazardous energy when employees service and maintain machines and equipment.  This violation was discovered on March 04, 2013, in the manufacturing and assembly areas; where the employer did not develop, document and utilize procedures for the control of potentially hazardous energy when employees serviced and maintained the following machines and equipment:            a. Tyler Manufacturing power press located in the production / assembly areas.         b. Stafast power press located in the production / assembly areas.

Issued

2013-08-12 00:00:00

Abate by

2013-08-19 00:00:00

Penalty

Initial $56000.00 · Current $28000.00 Reduced

General-duty citation text

29 CFR 1910.212(a)(3)(ii): The point of operation of machines whose operation exposed an employee to injury, wa not guarded:       The employer does not ensure that point(s) of operation of machinery are guarded to prevent employee(s) from having any part of their body in the danger zone(s) during operating cycle(s).  This violation was discovered on February 12, 2013, in the manufacturing and assembly areas; where at least two (2) employees were exposed to point of operation hazards:     a. While operating a Tyler Machinery power press in the assembly area.     b. While operating a Stafast t-nut press located in the assembly area.