OSHA Inspection: THE J.J. RYAN CORPORATION REX FORGE DIVISION

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.22(a)(2): Floor(s) of workroom(s) were not maintained in a clean and, so far as possible, a dry condition:    Hot Press:  On, or about, May 29, 2013, a transformer located in front of a wall mounted circuit breaker panel behind Press #49 box was sitting in a pool of water.

Issued

Nov 26, 2013

Abate by

Apr 15, 2014

Penalty

Initial $4,950 · Current $2,970 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:     A.  Weld Shop:  On, or about, May 29, 2013, the forktruck platform provided for use by maintenance staff was not provided with a top rail that was 42 inches, nomial, above the work platform and midrails.     B.  Inspection Department:  On, or about, July 29, 2013, fall protection was not used when maintenance personnel accessed the top of Wheelabrator #1 to change the elevator cables or perform other maintenance operations.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.176(b): Storage of material created a hazard:    Hot Press, Induction Coil Storage Rack:  On, or about, June 3, 2013, several main support rails and diagonal support members were bent and twisted on the end of the storage rack system.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.184(e)(1): Alloy steel sling(s) did not have permanently affixed durable identification stating size, grade, rated capacity, and reach:     A.  Die Shop:  On, or about, May 29, 2013, a four legged sling used to move dies was not provided with an identification tag.     B.  Die Room:  On, or about, June 3, 2013, a two legged shop-made sling used to support fixtures while TIG welding was not provided with an identification tag.    C.  Weld Shop:  On, or about, July 29, 2013, a single legged shop-made sling used to move dies was not provided with an identification tag.

Issued

Nov 26, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.184(e)(3)(i): A thorough periodic inspection of alloy steel chain slings was not made on a regular basis and/or were done at intervals greater than once every 12 months:  A.  Die Room:  On, or about, June 3, 2013, a two legged shop-made sling used to support fixtures while TIG welding was not provided with annual documented inspections.  B.  Weld Shop:  On, or about, July 29, 2013, a single legged shop-made sling used to move dies was not provided with annual documented inspections.

Issued

Nov 26, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.184(f)(1): The employer used wire rope sling(s) that did not have permanently affixed and legible identification markings as prescribed by the manufacturer:  Steel Yard:  On, or about, May 29, 2013, two single legged wire rope slings used to lift bundles of steel stock were not provided with an identification tag.

Issued

Nov 26, 2013

Penalty

Initial $3,960 · Current $2,376 Reduced

General-duty citation text

29 CFR 1910.212(a)(5): Where the periphery of fan blades was less than seven feet from the cloor or working level, fan blade guards were either not provided or had openings larger than one half inch:    A.  Hot Press:  On, or about, May 29, 2013, the motor fan cover was missing on the conveyor at Trim Press #48.       B.  Hot Press:  On, or about, June 3, 2013, the guard provided on the pedestal fan used at Press #48 was pulled back, allowing access to the fan blades.

Issued

Nov 26, 2013

Penalty

Initial $3,960 · Current $2,376 Reduced

General-duty citation text

29 CFR 1910.254(d)(7): Electrode holders when not in use were not so placed that they could not make electrical contact with persons, conducting objects, fuel or compressed gas tanks:     A.  Hot Press:  On, or about, May 29, 2013, an electrode was left in the electrode holder of the ABCO welding unit.      B.  Maintenance Shop:  On, or about, June 3, 2013, an electrode was left in the electrode holder of the Miller welding unit.  The welding unit was on.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

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:    Maintenance Shop, Break Area:  On, or about, June 3, 2013, the following electrical equipment was not used or installed in accordance with the listing or labeling instructions:    A.  A portable fan designed for use in a residential location was used.      B.  A knockout box designed for permanent mounting was provided with a flexible cord and was hanging from a receptacle.  It was used to energize two battery chargers for portable tools.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.303(b)(7): 29 CFR 1910.303(b)(7):  Electrical equipment was not installed in a neat and workmanlike manner:    A.  Steel Yard:  On, or about, May 29, 2013, doors on electrical control boxes were not provided with proper latches to be securely closed:    1.  Horizontal Band Saw #3, Hem Saw:  The door provided on the main electrical box was wired shut because the latch was broken.    2.  Horizontal Band Saw #4:  The door provided on the main electrical box was kept closed by a chained pin because the door did not appear to close properly.      B.  Hot Press:      1.  On, or about, May 29, 2013, the conveyor provided at Trim Press #48 had an on/off control box that was left open for access to the on/off switch.  The opening in the cover did not match the switch configuration that was installed.    2.  On, or about, May 29, 2013, the transfer conveyor provided on Forge Press #48 had an on/off control box that was left open for access to the on/off switch.  The opening in the cover did not match the switch configuration that was installed.      3.  On, or about, June 3, 2013, an opening was left in the front of the Cutler-Hammer enclosure for the Line #46 Induction Heater electrical service located in the electrical shed.  The opening was created when a space was left between the enclosure wall and the circuit breaker.    4.  On, or about, June 3, 2013, expanded metal was used to replace the the standard electrical box covers provided on both the transfer conveyor and fan on/off switch at Press #46.    5.  On, or about, June 3, 2013, the electrical box provided at Trim Press #45 was secured shut with a piece of wire.    6.  On, or about, June 3, 2013, an extension cord had been used to energize two refrigerators next to the Press #48 work bench.  The power cords provided for each appliance had been wired into a single female attachment to be plugged into the extension cord.     7.  On, or about, June 3, 2013, the main electrical control box provided at Forge Press #43 was secured closed with a piece of wire.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 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:     A.  Die Shop:  On, or about, May 29, 2013, two disconnect boxes located behind the DooSan CNC machine were blocked by a tool cart.    B.  Electrical Shed Behind Hot Press #47:  On, or about, June 3, 2013, items such as boxes, propane tanks, shafts, machine parts, slings and buckets had been stored in the working space in front of the large heater control enclosures and in front of circuit breaker panel.    C.  Weld Shop:    On, or about, July 29, 2013, the General Battery Charger was located in the working space in front of the Cutler-Hammer circuit breaker box.      D.  Shipping:  On, or about, July 29, 2013, the shipping bench was located in front of a bank of disconnects, including a wall mounted circuit breaker box.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings were not protected from abrasions:     A.  Hot Press:      1.  On, or about, May 29, 2013, conduit that connected the on/off switch to the motor on the #48 trim press conveyor was pulled from the motor connection, exposing the inner conductors to damage.    2.  On, or about, June 3, 2013, conduit that connected the on/off switch to the motor on the #46 trim press conveyor was pulled from the motor connection, exposing the inner conductors to damage.    3.  On, or about, June 3, 2013, conduit provided below a secondary control station mounted Forge Press #43 was broken, exposing the inner conductors.    4.  On, or about, June 3, 2013, the power cord provided for the outfeed conveyor on Forge Press #43 was split and pulled at the plug connection.     B.  Maintenance Shop:  On, or about, June 3, 2013, the power cord provided on the black pedestal fan was not provided with a fitting or grommet to protect the inner conductors from abrasions.    C.  Inspection Department:  On, or about, June 3, 2013, conduit provided for the Conveyor #2 motor controls was broken in two places, exposing the inner conductors to damage and abrasions.

Issued

Nov 26, 2013

Penalty

Initial $4,950 · Current $2,970 Reduced

General-duty citation text

29 CFR 1910.305(b)(2)(i): Pull boxes, junction boxes, and fittings were not provided with covers approved for the purpose:    A.  Steel Yard:  On, or about, May 29, 2013, the cover was missing on the length gauge wiring conduit provided on Slugger Shear #2.      B.  Hot Press:      1.  On, or about, May 29, 2013,  the cover was missing on the motor on the fan used to provide ventilation to the operator's station at Trim Press #50.    2.  On, or about, May 29, 2013, Pump Station Induction Heater area behind Press 49:  The cover provided on the type LB box at the transformer connection was not secured at the Pump Staion Induction Heater area behind Press #49.    3.  On, or about, May 29, 2013, at the Inspection Bench located at Press #48, the fan motor cover was missing and electrical tape had been used to cover the opening and a junction box mounted in the bench conduit was missing a cover.    4.  On, or about, June 3, 2013, a cover was not provided on the LB box provided on the main electrical box on Trim Press #45.      5.  On, or about, June 3, 2013, two covers were missing on the electrical conduit mounted on Forge Press #43.      6.  On, or about, June 3, 2013, a cover had not been provided on a knockout box mounted on the sprayer frame for the sprayer motor provided at Forge Press #43.    7.  On, or about, June 3, 2013, the fan control box provided on the large fan at Trim Press #44 was missing the front cover.      C.  Inspection Department:  On, or about, July 29, 2013, the cover was missing on the motor connection for Conveyor #2.

Issued

Nov 26, 2013

Abate by

Jun 30, 2014

Penalty

Initial $6,930 · Current $4,158 Reduced

General-duty citation text

29 CFR 1910.332(b)(1): Employees were not familiar with the safety-related work practices required by 1910.331 through 1910.335 that pertained to their respective job assignments:    Production Areas:  On, or about, June 3, 2013, employee(s) who performed work on electrical equipment including live trouble-shooting and verifying whether or not electrical equipment was properly de-energized using test equipment, were not familiar with the safety related work practices that were needed to protect them from electrical hazards such as, but not limited to, electric shock, electrocution, burns and shrapnel injuries.  An employee who worked as a plant electrician had been trained in general topics related to electrical safety, but had not received training at the facility level so that the level of protection needed for different voltage classes and types of work performed was understood.

Issued

Nov 26, 2013

Abate by

Jun 30, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.333(a)(2): Where exposed live parts were not deenergized, other safety related work practices were not used to protect employees who could be exposed to the electrical hazards involved:     Facility:  On, or about, June3, 2013, the company had not developed and implemented safe work procedures to be used when employees worked on or near live electrical equipment to perform live trouble-shooting or to verify that it was properly de-energized.

Issued

Nov 26, 2013

Abate by

Jun 30, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.333(b)(2)(i): The employer did not maintain a written copy of the procedures outlined in paragraph (b)(2) of 29 CFR 1910.333 and did not make it available for inspection by the Assistant Secretary of Labor and his or her authorized representatives:    Facility:  On, or about, September 13, 2013, the company did not have either the regulation referenced in 29 CFR 1910.333 or equivalent procedures that required that all electrical equipment be verified as de-energized using test equipment in accordance with 29 CFR 1910.333.

Issued

Nov 26, 2013

Abate by

Jun 30, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.335(a)(1)(i): Employees working in areas where there were potential electrical hazards were not using electrical protective equipment that was appropriate for the specific parts of the body to be protected and for the work to be performed:    Production Areas:  On, or about, June 3, 2013, personal protective equipment such as, but not limited to, voltage rated gloves, fire resistive clothing, fire resistive face shields, balaclavas, hard hats and hearing protection were not provided to employees who performed live electrical work, including trouble-shooting, or who verified that electrical equipment was properly de-energized.  At the time of the inspection, the electrician had been provided with Class 3 voltage rated gloves that were not designed for everyday testing and trouble-shooting activities and a face shield that was not rated for electrical hazards.      Abatement Note:  The use of time delay fuses in electrical equipment may increase the cycle time of protective equipment.  An arc flash study may be necessary to determine the proper level of personal protective equipment that is required to be provided for employees to use.

Issued

Nov 26, 2013

Penalty

Initial $198 · Current $118 Reduced

General-duty citation text

29 CFR 1910.304(a)(2): Grounded conductors were attached to terminals or leads so as to reverse designated polarity:    Die Shop:  On, or about, May 29, 2013, a wall mounted receptacle that was used to energize a work light at EDM #3 was found to have reversed polarity.    THE J.J. RYAN CORPORATION REX FORGE DIVISION WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD WHICH WAS CONTAINED IN OSHA INSPECTION 314402165, CITATION 3, ITEM 1b ISSUED ON NOVEMBER 29, 2010, WITH RESPECT TO THE WORKPLACE LOCATED AT 355 ATWATER STREET, PLANTSVILLE, CONNECTICUT.  THE FINAL ORDER DATE FOR THE CITATION WAS ON JANUARY 1, 2011.

Issued

Nov 26, 2013

Penalty

Initial $9,900 · Current $5,940 Reduced

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:     A.  Hot Press:  On, or about, June 3, 2013, an extension cord was used to energize two refrigerators located next to the work bench behind Press #48.    B.  Maintenance Shop:      1.  On, or about, June 3, 2013, a Black and Decker toaster oven and a white refrigerator were energized through an extension cord that was plugged into a duplex outlet.    2.  On, or about, June 3, 2013, a quad receptacle provided for use in the Electricians Shop was energized through a flexible cord that was wired into a duplex receptacle box at another workbench.  The quad receptacle was used to energize a radio and battery chargers.       C.  Weld Shop:  On, or about, July 29, 2013, the Haier refrigerator was energized through an extension cord.    D.  Inspection Department:  On, or about, July 29, 2013, extension cords were used to energize the following equipment:      1.  A work light provided for the work area in front of Wheelabrator #2.  2.  A  Hotpoint microwave oven  located on a work bench near Conveyor #5.    THE J.J. RYAN CORPORATION REX FORGE DIVISION WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR IT EQUIVALENT STANDARD WHICH WAS CONTAINED IN OSHA INSPECTION 314397720, CITATION 1, ITEM 4a, ISSUED ON JUNE 7, 2010, WITH RESPECT TO THE WORKPLACE LOCATED AT 355 ATWATER STREET, PLANTSVILLE, CONNECTICUT. THE FINAL ORDER DATE FOR THE CITATION WAS ON JULY 2, 2010.

Issued

Nov 26, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.334(a)(2)(ii): When there was a defect or evidence of damage that could expose an employee to injury, the defective or damaged item was not removed from service until the repairs and tests necessary to render the electric equipment safe had been made:  Hot Press:  On, or about, June 3, 2013, the following electrical cords were found to be damaged:  A.  The outer jacket provided on the extension cord used to energize two refrigerators located behind Press #43 was damaged and wrapped with duct tape.   B.  The power cord provided for the outfeed conveyor on Forge Press #43 was split and pulled at the plug connection.   THE J.J. RYAN CORPORATION REX FORGE DIVISION WAS PREVIOUSLY CITED FOR A VIOLATION OF THIS OCCUPATIONAL SAFETY AND HEALTH STANDARD OR ITS EQUIVALENT STANDARD WHICH WAS CONTAINED IN OSHA INSPECTION 314397720, CITATION 1, ITEM 4b ISSUED ON JUNE 7, 2010 WITH RESPECT TO THE WORKPLACE LOCATED AT 355 ATWATER STREET, PLANTSVILLE, CONNECTICUT.  THE FINAL ORDER DATE FOR THE CITATION WAS ON JULY 2, 2010.

Issued

Nov 26, 2013

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:   Electrician's Shop:  On, or about, June 3, 2013. a knockout was missing from the side of the quad receptacle box that was used to energize a radio and battery chargers.