OSHA Inspection: ONEIDA CASTING GROUP

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $2,400 · Current $720 Reduced

Hazardous substances 81108111

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:    a) Molding area, on or about 5/22/13: An employee working in the molding area as a molder, was exposed to continuous noise at a level of 88.5 % of the dose of the permissible exposure limit (PEL). The equivalent dBA for the 88.5 % dose is 89.1 dBA calculated as the 8-hour time weighted sound pressure level. Sampling was conducted on 5/22/13 for 259 minutes. A zero increment was included for the 221 minutes not sampled. Employees hired after 10/4/12 were not included in the hearing conservation program which included hearing conservation training, supervision of hearing protector use and instruction on proper fit and care.    b) Grinding area, on or about 5/22/13: An employee working in the grinding area as a grinder, was exposed to continuous noise at a level of 248 % of the dose of the permissible exposure limit (PEL). The equivalent dBA for the 248 % dose is 95.6 dBA calculated as the 8-hour time weighted sound pressure level. Sampling was conducted on 5/22/13 for 263 minutes. A zero increment was included for the 217 minutes not sampled. Employees hired after 10/4/12 were not included in the hearing conservation program which included hearing conservation training, supervision of hearing protector use and instruction on proper fit and care.    Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(i)(4): The employer did not provide training in the use and care of all hearing protectors provided to employees:  a) Molding area, on or about 5/22/13: An employee working in the molding area as a molder was not trained in the use and care of hearing protection.  See Citation 1, Item 1a for exposure summary.  b) Grinding area, on or about 5/22/13: An employee working in the grinding area as a grinderwas not trained in the use and care of hearing protection.  See Citation 1, Item 1a for exposure summary.  Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.95(i)(5): The employer did not ensure proper initial fitting and supervise the correct use of all hearing protectors:  a) Molding area, on or about 5/22/13: An employee working in the molding area as a molder was not fitted and supervised in the use of hearing protection.  See Citation 1, Item 1a for exposure summary.  b) Grinding area, on or about 5/22/13: An employee working in the grinding area as a grinder was not fitted and supervised in the use of hearing protection.  See Citation 1, Item 1a for exposure summary.  Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 81108111

General-duty citation text

29 CFR 1910.95(k)(1): The employer did not train each employee who is exposed to noise at or above an 8-hour time-weighted average of 85 decibels in accordance with the requirements of 29 CFR 1910.95(k). The employer did not institute a training program and ensure employee participation in the program:  a) Molding area, on or about 5/22/13: An employee working in the molding area as a molder was not trained in hearing conservation.  See Citation 1, Item 1a for exposure summary.  b) Grinding area, on or about 5/22/13: An employee working in the grinding area as a grinder was not trained in hearing conservation.  See Citation 1, Item 1a for exposure summary.  Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $1,600 · Current $480 Reduced

General-duty citation text

29 CFR 1910.132(a): Protective equipment, including personal protective equipment for eyes, face, head, and extremities, protective clothing, respiratory devices, and protective shields and barriers was not provided, used, and/or maintained.     a) Foundry area, on or about 5/30/13: Employees were exposed to burn injuries when protective sleeves for forearms were not used during pours of molten metal from ladles into molds.    Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(f)(3)(iii): The employer did not retrain employees when inadequacies in the affected employee's use of PPE indicated the employee had not retained the requisite understanding.  a) Foundry area, on or about 5/30/13: Employees, not wearing required personal protective equipment, were exposed to burn injuries during pours of molten metal from ladles into molds and were not provided with retraining on the availability and use of personal protective equipment including, but not limited to, faceshields, forearm protection and suitable gloves closed at the wrists.  Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.133(a)(1): The employer did not ensure that each affected employee uses appropriate eye or face protection when exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially injurious light radiation:  a) Foundry area, on or about 5/30/13: The employer did not ensure that employees exposed to burn injuries used faceshields during pours of molten metal from ladles into molds.  Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.138(b): The employer did not base the selection of the appropriate hand protection on an evaluation of the performance characteristics of the hand protection relative to the task(s) to be performed, conditions present, duration of use, and the hazards and potential hazards identified:  a) Foundry area, on or about 5/30/13: The employer did not select appropriate hand protection for burn hazards to employee's hands when gloves opened at the wrists were used when pouring molten metal into molds.  Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $2,800 · Current $840 Reduced

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(a)(2): A respirator was not provided by the employer to each employee when such equipment was necessary to protect the health of the employee:    a) Shakeout operations, on or about 5/24/13: A bobcat operator overexposed to total dust while cleaning up sand from shakeout operations was not provided with a respirator.  A written respiratory protection program was not implemented.  See Citation 1, Item 3g for exposure summary.     b) Clean room, on or about 5/30/13:  A grinder in the cleanroom overexposed to respirable quartz (silica) was not provided with a respirator. Engineering controls employed did not reduce exposure to below the PEL.  A written respiratory protection program was not implemented.  See Citation 1, Item 3h for exposure summary.    Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(c)(1): A written respiratory protection program that included the provisions in 29 CFR 1910.134(c)(1)(i) - (ix) with worksite specific procedures was not established and implemented for required respirator use:  a) Muller cleaning operations, on or about 5/24/13: A written respiratory protection program was not implemented for a maintenance employee cleaning the inside of the muller who wore an N95 air purifying half face respirator.  See Citation 1, Item 3g for exposure summary.  b) Shakeout operations, on or about 5/24/13: A written respiratory protection program was not implemented for a bobcat operator moving sand from shakeout operations who was overexposed to total dust without wearing a respirator.  See Citation 1, Item 3g for exposure summary.  c) Furnace area, on or about 5/22/13: A written respiratory protection program was not implemented for an employee cleaning around the furnace and in the cupola who wore a N95 air purifying half face respirator.  See Citation 1, Item 3g for exposure summary.  d) Furnace area, on or about 5/22/13: A written respiratory protection program was not implemented for an employee cleaning the furnace and cupola who wore a N95 air purifying half face respirator.  See Citation 1, Item 3h for exposure summary.   Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(d)(1)(iii): The employer did not identify and evaluate the respiratory hazard(s) in the workplace; including a reasonable estimate of employee exposures to respiratory hazards and identification of the contaminant's chemical state and physical form:  a) Muller cleaning operations, on or about 5/24/13: The employer did not evaluate a reasonable estimate of the respiratory hazards for a maintenance employee cleaning the inside of the muller.  See Citation 1, Item 1g for exposure summary.  b) Shakeout operations, on or about 5/24/13: The employer did not evaluate a reasonable estimate of the respiratory hazards for a bobcat operator moving sand from shakeout operations.  See Citation 1, Item 1g for exposure summary.  c) Furnace area, on or about 5/22/13: The employer did not evaluate a reasonable estimate of the respiratory hazards for an employee engaged in furnace cleaning operations.  See Citation 1, Item 1g for exposure summary.  d) Furnace area, on or about 5/22/13: The employer did not evaluate a reasonable estimate of the respiratory hazards for an employee engaged in furnace cleaning operations.  Seet Citation 1, Item 1h for exposure summary.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(e)(1): The employer did not provide a medical evaluation to determine the employee's ability to use a respirator, before the employee was fit tested or required to use the respirator in the workplace:  a) Muller cleaning operations, on or about 5/24/13: The employer did not provide a medical evaluation to a maintenance employee cleaning the inside of the muller who wore a N95 air purifying half face respirator.  See Citation 1, Item 3g for exposure summary.  b) Furnace area, on or about 5/22/13: The employer did not provide a medical evaluation to an employee engaged in furnace cleaning operations who wore a N95 air purifying half face respirator.  See Ciation 1, Item 3g for exposure summary.  c) Furnace area, on or about 5/22/13: The employer did not provide a medical evaluation to an employee cleaning the cupola who wore a N95 air purifying half face respirator.  See Citation 1, Item 3h for exposure summary.  Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(f)(1): The employer did not ensure that employee(s) required to use a tight-fitting facepiece respirator passed the appropriate qualitative fit test (QLFT) or quantitative fit test (QNFT):  a) Muller cleaning operations, on or about 5/24/13: The employer did not ensure that a maintenance employee cleaning the inside of the muller who wore a N95 air purifying respirator for an overexposure to total dust had passed an appropriate fit test.  See Citation 1, Item 3g for exposure summary.  b) Furnace area, on or about 5/22/13: The employer did not ensure that an employee engaged in furnace cleaning operations who wore a N95 air purifying respirator for an overexposure to total dust had passed an appropriate fit test.  See Citation 1, Item 3g for exposure summary.    c) Furnace area, on or about 5/22/13: The employer did not ensure that an employee engaged in furnace cleaning operations who wore a N95 air purifying respirator for an overexposure to silica had passed an appropriate fit test.  See Citation 1, Item 3h for exposure summary.     Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.134(k): The employer did not provide comprehensive, understandable training which did not occur annually and/or more often if necessary:  a) Muller cleaning operations, on or about 5/24/13: The employer did not provide a maintenance employee cleaning the inside of the muller who wore a N95 air purifying half face respirator with adequate respirator training.  See Citation 1, Item 3g for exposure summary.  b) Furnace area, on or about 5/22/13: The employer did not provide an employee engaged in furnace cleaning operations who wore a N95 air purifying half face respirator with adequate respirator training.  See Citation 1, Item 3g for exposure summary.   c) Furnace area, on or about 5/22/13: The employer did not provide an employee engaged in furnace cleaning operations who wore a N95 air purifying half face respirator with adequate respirator training.  See Citation 1, Item 3h for exposure summary.   Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 9135

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of Particulates not otherwise regulated (Total Dust) listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 15 milligrams per cubic meter (mg/m3):   a) Muller cleaning operations, on or about 5/24/13: A maintenance employee cleaning the inside of the muller was exposed to an 8 -hour time weighted average (TWA) of total dust at 17.3 milligrams per cubic meter (mg/m3), or 1.2 times the permissible exposure limit (PEL) of 15 mg/m3, during the 345 minute sampling period. A zero increment was included for the 135 minutes not sampled.    b) Shakeout operations, on or about 5/24/13: A bobcat operator moving sand from shakeout operations was exposed to an 8-hour TWA of total dust at 16.3 mg/m3, or 1.1 times the PEL of 15 mg/m3, during 413 minute sampling period. A zero increment was included for the 67 minutes not sampled.    c) Furnace area, on or about 5/22/13: An employee engaged in furnace cleaning operations was exposed to an 8-hour TWA of total dust at 30.3 mg/m3 or 2 times the PEL of 15 mg/m3, during the 442 minute sampling period. A zero increment was included for the 38 minutes not sampled.   Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.1000(c): An employee(s) was exposed to respirable quartz (silica) in excess of the 8-hour time weighted average limits listed in Table Z-3:  a) Clean room, on or about 5/30/13: A grinder was exposed to an 8-hour time weighted average (TWA) of silica at 1.03 mg/m3, or 1.2 times the PEL of .893 mg/m3, during 275 minute sampling period. A zero increment was included for the 205 minutes not sampled.   a) Furnace area, on or about 5/22/13: An employee engaged in furnace cleaning operations was exposed to an 8-hour TWA of silica at 2.85 mg/m3 or 6.6 times the PEL of .435 mg/m3, during the 442 minute sampling period. A zero increment was included for the 38 minutes not sampled.  Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Dec 31, 2013

Penalty

Initial $0 · Current $0

Hazardous substances 90109135

General-duty citation text

29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d):  a) Muller cleaning operations, on or about 5/24/13: The employer did not determine or implement feasible controls for a maintenance employee cleaning the inside of the muller who was overexposed to total dust.  See Citation 1, Item 3g for exposure summary.  b) Shakeout operations, on or about 5/24/13: The employer did not determine or implement feasible controls for a bobcat operator moving sand from shakeout operations who was overexposed to total dust.  See Citation 1, Item 3g for exposure summary.  c) Furnace area, on or about 5/22/13: The employer did not determine or implement feasible controls for an employee performing furnace cleaning operations who was overexposed to total dust.  See Citation 1, Item 3g for exposure summary.  d) Clean room, on or about 5/30/13: The employer did not determine or implement feasible controls for a grinder who was overexposed to respirable quartz (silica).  See Citation 1, Item 3h for exposure summary.  e) Furnace area, on or about 5/22/13: The employer did not determine or implement feasible controls for an employee performing furnace cleaning operations who was overexposed to respirable quartz (silica).  See Citation 1, Item 3h for exposure summary.  Abatement documentation must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $2,000 · Current $600 Reduced

General-duty citation text

29 CFR 1910.146(c)(1): The employer did not evaluate the workplace to determine if any spaces were permit-required confined spaces:    a) Throughout the facility, on or about 5/7/13: The employer did not evaluate the work place for the presence of permit required confined spaces including, but not limited to the furnace cupola and muller.    Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(c)(2): The employer did not inform exposed employees, by posting danger signs or by any other equally effective means, of the existence and location of and the danger posed by the permit spaces:   a) Throughout the facility, on or about 5/7/13: Permit required confined space signs were not posted at or near spaces including, but not limited to the furnace cupola and muller.   Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 7, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(c)(4): When the employer decided that its employees would enter permit spaces, the employer did not develop and implement a written permit space entry program that complied with 29 CFR 1910.146:  a) Throughout the facility, on or about 5/7/13: A written permit required confined space program was not implemented in the work place for entry into spaces including, but not limited to, the furnace cupola and muller.  Abatement certification must be submitted for this item.

Issued

Sep 27, 2013

Abate by

Oct 17, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(e)(1): Before entry was authorized, the employer did not document the completion of measures required by 29 CFR 1910.146(d)(3) by preparing an entry permit:   a) Throughout the facility, on or about 5/7/13: Permits were not documented prior to entry into the cupola for cleaning operations involving locking out natural gas sources and dissipation of thermal energy.   b) Throughout the facility, on or about 5/7/13: Permits were not documented prior to entry into the muller and the muller bucket pit involving locking out electrical energy and controlling potential energy.   Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.146(g)(1): The employer did not provide training so that all employees whose work was regulated by 29 CFR 1910.146 (permit required confined spaces) acquired the understanding, knowledge, and skills necessary for the safe performance of the duties assigned under 29 CFR 1910.146:  a) Furnace area, on or about 5/7/13: Training on permit required confined spaces was not provided for employees entering the furnace cupola for cleaning operations.  b) Muller area, on or about 5/7/13: Training on permit required confined spaces was not provided for employees entering the muller for cleaning operations.  Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Oct 17, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(4): Procedures were not developed, documented, and utilized for the control of potentially hazardous energy when employees were engaged in activities covered by this section:  a) Throughout the facility, on or about 5/7/13: Energy control procedures were not developed for furnace and cupola cleaning operations involving locking out natural gas sources and dissipation of thermal energy.  b) Throughout the facility, on or about 5/7/13: Energy control procedures were not developed for the muller involving locking out of electrical energy and controlling potential energy.  Abatement certification must be submitted for these items.

Issued

Sep 27, 2013

Abate by

Nov 1, 2013

Penalty

Initial $2,400 · Current $720 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:    a) Throughout the facility, on or about 5/7/13: Initial training on the hazards of chemicals in the workplace including but not limited to silica and heavy metals was not provided for grinders and molders, hired after 10/4/12.    Abatement certification must be submitted for this item.