OSHA Inspection: RELIABLE CASTINGS CORPORATION

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $5,500 · Current $4,000 Reduced

General-duty citation text

29 CFR 1910.22(c): Covers and/or guardrails were not provided to protect personnel from the hazards of open pits, tanks, vats, ditches, etc.    a) Reliable Castings Corporation - Sidney, Ohio: On or about October 6, 2013, the employer did not assure that heat treat oven #1 was equipped with guardrails.  Employees working in the heat treat area were exposed to falls of approximately 6.5ft when loading/unloading materials into heat treat ovens.      b) Reliable Castings Corporation - Sidney, Ohio: On or about October 6, 2013, the employer did not assure that heat treat oven #2 was equipped with guardrails.  Employees working in the heat treat area were exposed to falls of approximately 6.5ft when loading/unloading materials into heat treat ovens.      c) Reliable Castings Corporation - Sidney, Ohio: On or about September 30, 2013, the employer did not assure that heat treat oven #3 was equipped with guardrails.  Employees working in the heat treat area were exposed to falls of approximately 6.5ft when loading/unloading materials into heat treat ovens.      d) Reliable Castings Corporation - Sidney, Ohio: On or about October 5, 2013, the employer did not assure that heat treat oven #1 was equipped with guardrails.  Employees working in the heat treat area were exposed to falls of approximately 6.5ft when loading/unloading materials into heat treat ovens.      e) Reliable Castings Corporation - Sidney, Ohio: On or about October 6, 2013 the employer did not assure that the quench tank was equipped with guardrails.  Employees working in the heat treat area were exposed to falls into the quench tank which contained water that was approximately 160 degrees Fahrenheit.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(a)(1): Every stairway floor opening was not guarded by a standard railing constructed in accordance with paragraph (e) of this section on all exposed sides (except at the entrance to the stairway):    a) Reliable Castings Corporation - Sidney, OH: On or about September 17, 2013, employees working in the heat treat area were exposed to falls of approximately 6.5ft in that the stairway floor opening located in the northwest corner was not guarded by a standard guardrail in accordance with 29 CFR 1910.23(e).

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.23(c)(1): Open-sided floors and/or platforms four feet or more above adjacent floor or ground level were not guarded with standard railings (or equivalent) and toeboards:    a) Reliable Castings Corporation - Sidney, Ohio: On or about October 6, 2013, employees working in the heat treat area were exposed to falls of approximately 6.5ft in that the open sided floor, located at the south side of heat treat oven #2, was not equipped with standard guardrails in accordance with 29 CFR 1910.23(e).     b) Reliable Castings Corporation - Sidney, Ohio: On or about September 30, 2013, employees working in the heat treat area were exposed to falls of approximately 6.5ft in that the open sided floor, located at the north side of heat treat oven #3, was not equipped with standard guardrails in accordance with 29 CFR 1910.23(e).    c) Reliable Castings Corporation - Sidney, Ohio: On or about October 5, 2013, employees working in the heat treat area were exposed to falls of approximately 6.5ft in that the open sided floor, located at the south side of heat treat oven #4, was not equipped with standard guardrails in accordance with 29 CFR 1910.23(e).

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $6,600 · Current $4,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to assure that furnace tenders in the ACO building wore flame resistant clothing to protect against injury from molten metal splash.  Employees are exposed to molten metal when putting scrap into furnaces, adding gas, and taking samples.    b) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer failed to assure Cell #3 operators who deposit scrap parts into Furnace #2 wore flame resistant clothing to protect the upper and lower body against injury from molten metal splash.       c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to assure employees who deposit scrap parts into Furnace #1 were provided with and wore flame resistant clothing for the lower body to protect against injury from molten metal splash.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $6,600 · Current $4,000 Reduced

General-duty citation text

29 CFR 1910.132(d)(1)(i): When the employer had assessed the workplace hazard(s) and determined that hazard(s) were present, the employer did not select and/or use the types of personal protective equipment that would protect the affected employee from the hazards identified in the hazard assessment:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to perform an adequate hazard assessment which would necessitate the proper protective equipment to be worn by employees exposed to hazards associated with molten aluminum metal.  Furnace tenders in the ACO building were not protected from burn injuries to the head.      b) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to perform an adequate hazard assessment to determine proper protective equipment (PPE) to be worn by employees exposed to hazards associated with molten aluminum metal.  Employees who operated Cell #3 were exposed to molten aluminum metal splash when depositing scrap parts into Furnace #2 in that the employer did not necessitate PPE that would protect employees from burn injuries to the face and head.      c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to perform an adequate hazard assessment to determine proper personal protective equipment (PPE) to be worn by employees tasked with depositing scrap parts into Furnace #1.  Employees were exposed to molten aluminum metal splash in that the employer did not necessitate PPE that would protect employees from burn injuries to the head.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.133(a)(1): Protective face equipment was not required where there was a reasonable probability of injury that could be prevented by such equipment:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer failed to assure Cell #3 operators who deposit scrap parts into Furnace #2 wore face protection to protect against injury from molten metal splash.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.135(a)(1): The employer did not ensure that each affected employee wear a protective helmet when working in areas where there is a potential for injury to the head from falling objects:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to assure that furnace tenders in the ACO building were provided with and wore head protection to protect against injury from molten metal splash.  Employees are exposed to molten metal when putting scrap into furnaces, adding raw materials, and taking samples.    b) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer failed to assure employees Cell #3 operators who deposit scrap parts into Furnace #2 were provided with and wore head protection to protect against injury from molten metal splash.       c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer failed to assure employees who deposit scrap parts into Furnace #1 were provided with and wore head protection to protect against injury from molten metal splash.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $7,000 · Current $4,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about October 8, 2013, a periodic inspection of the energy control procedures was not performed to assure that lockout/tagout procedures and requirements of 29 CFR 1910.147 were being followed.  The employer did not assure that energy control procedures for Production Cells 1 and 3, located in ACO, were audited.

Issued

Dec 19, 2013

Abate by

Nov 16, 2015

Penalty

Initial $7,000 · Current $4,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the automated/robot ladle associated with Production Cell #1 was not equipped with guarding to protect employees from pinch points and molten aluminum metal hazards. Employees that access the hazard area were exposed to the pinch points of the moving ladle, molten aluminum metal, and a pinch point created between a scrap bin located below the ladle and devices as they rotate to the pouring station.    b) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that a pinch point created when Production Cell #1 devices approach the catcher station, was adequately guarded.  Employees pulling parts and/or operating the production cell were exposed to being caught between devices and the catcher table.      c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that pinch points, created when Production Cell #1 devices tilt to the horizontal position, were guarded.  Employees accessing the production cell?s turn table were exposed to crush/caught-by hazards as the device tilted.     d) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that pinch points, created when molds on production Cell #1 automatically close, were guarded.  Employees accessing the hazard area to remove parts or flashing or used compressed air in the mold were exposed to crushing and amputation injuries.    e) Reliable Castings Corporation - Sidney, Ohio:On or about July 22, 2013, the automated/robot ladles associated with Production Cell #2 were not equipped with guarding to protect employees from pinch points and molten aluminum metal hazards. Employees that access the hazard area were exposed to the pinch points of the moving ladles, molten aluminum metal, and a pinch point created between a scrap bin located below the ladles and devices as they rotate to the pouring stations.     f) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that a pinch point, created when Production Cell #2 devices approach the catcher station, was adequately guarded.  Employees pulling parts and/or operating the production cell were exposed to being caught between devices and the catcher table.      g) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that pinch points, created when Production Cell #2 devices tilt to the horizontal position, were guarded.  Employees accessing the production cell?s turn table were exposed to crush/caught-by hazards as the device tilted.     h) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that pinch points, created when molds on production Cell #2 automatically close, were guarded.  Employees accessing the hazard area to remove parts or flashing or used compressed air in the mold were exposed to crushing and amputation injuries.    i) Reliable Castings Corporation - Sidney, Ohio: On or about June 26, 2013, the automated/robot ladle associated with Production Cell #3 was not equipped with guarding to protect employees from pinch points and molten aluminum metal hazards. Employees that access the hazard area are exposed to the pinch points of the moving ladle and molten aluminum metal.     j) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that a pinch point created when Production Cell #3 devices approach the catcher station, was adequately guarded.  Employees pulling parts and/or operating the production cell were exposed to being caught between devices and the catcher table.      k) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that pinch points, created when Production Cell #3 devices tilt to the horizontal position, were guarded.  Employees accessing the production cell?s turn table were exposed to crush/caught-by hazards as the device tilted.     l) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that pinch points, created when molds on production Cell #3 automatically close, were guarded.  Employees accessing the hazard area to remove parts or flashing, spray the mold with insulator, or use compressed air in the mold were exposed to crushing and amputation injuries.    m) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the automated/robot ladle associated with Production Cell #4 was not equipped with guarding to protect employees from pinch points and molten aluminum metal hazards. Employees that access the hazard area were exposed to molten aluminum metal and a pinch point created between a barrier around the crucible and devices as they rotate to the pouring station.    n) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that a pinch point created when Production Cell #4 devices approach the catcher station, was adequately guarded.  Employees pulling parts and/or operating the production cell were exposed to being caught between devices and the catcher table.      o) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that pinch points, created when Production Cell #4 devices tilt to the horizontal position, were guarded.  Employees accessing the production cell?s turn table were exposed to crush/caught-by hazards as the device tilted.     p) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, the employer did not assure that pinch points, created when molds on production Cell #4 automatically close, were guarded.  Employees accessing the hazard area to remove parts or flashing, spray the mold with insulator, or use compressed air in the mold were exposed to crushing and amputation injuries.    q) Reliable Castings Corporation - Sidney, Ohio: On or about June 25, 2013, employees operating the Cincinnati Milacron Arrow 1500 located in the machine shop were exposed to injuries from the machine?s rotating parts and/or flying chips.  The machine was not adequately guarded in that employees were not prevented from accessing the hazard area during operation.    r) Reliable Castings Corporation - Sidney, Ohio: On or about June 25, 2013, employees operating the Quantum H410 CNC located in the machine shop were exposed to injuries from the machine?s rotating parts and/or flying chips.  The machine was not adequately guarded in that employees were not prevented from accessing the hazard area during operation.    s) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that employees were protected from pinch points created by moving parts of the #6 BMM Weston vertical sand molding machine located in the sand foundry.  Employees were exposed to pinch points created between the top platen and the flask/mold jacket as the platen moved over the mold and also as it lowered.    t) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that employees were protected from struck-by hazards and pinch points created by moving parts of the #7 BMM Weston vertical sand molding machine located in the sand foundry.  Employees were exposed to struck-by hazards as the machine flipped the flask/mold jacket and also to pinch points created between the top platen and the flask as the platen it lowered.    u) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer did not assure that employees were protected from pinch point and struck-by hazards created by moving parts of the Tabor machine located in the sand foundry.  Employees were exposed to struck-by hazards as the flask is turned over and to pinch points as the mold is placed down.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $70,000 · Current $30,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to crush/struck-by hazards while servicing and/or changing molds on Cell #4.  The employer failed to develop, document and use procedures that would control hazardous energy sources of the equipment.       b) Reliable Castings Corporation - Sidney, Ohio: On or about October 3, 2013, employees were exposed to crush/struck-by hazards while servicing and/or changing molds on Cell #3.  The employer failed to use procedures that would control hazardous energy sources of the equipment.    c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to crush/struck-by hazards while servicing or changing molds on Cell #2.  The employer failed to use procedures that would control hazardous energy sources of the equipment.    d) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to crush/struck-by hazards while servicing or changing molds on Cell #1.  The employer failed to use procedures that would control hazardous energy sources of the equipment.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(2): The machine or equipment was not turned off or shut down using the procedures established for the machine or equipment:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to injuries associated crush/struck-by hazards while maintaining molds located at production Cell #4.  The employer failed to assure the equipment was shut down and energy control application steps were followed prior to employees performing servicing and/or mold setup operations.      b) Reliable Castings Corporation - Sidney, Ohio: On or about October 8, 2013, employees were exposed to injuries associated crush/struck-by hazards while maintaining molds located at production Cell #3.  The employer failed to assure the equipment was shut down and energy control application steps were followed prior to employees performing servicing and/or mold setup operations.      c) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to injuries associated crush/struck-by hazards while maintaining molds located at production Cell #2.  The employer failed to assure the equipment was shut down and energy control application steps were followed prior to employees performing servicing and/or mold setup operations.      d) Reliable Castings Corporation - Sidney, Ohio: On or about July 30, 2013, employees were exposed to injuries associated crush/struck-by hazards while maintaining molds located at production Cell #1.  The employer failed to assure the equipment was shut down and energy control application steps were followed prior to employees performing servicing and/or mold setup operations.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $60,500 · Current $30,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, employees working at Cell #3 were exposed to hazards associated molten aluminum splash.  The employer failed to guard the side well of Furnace #2 to protect Cell #3 workers from burn injuries while performing tasks such as, but not limited to, staging scrap metal, sweeping, operating the cell's turn table and/or saw.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $5,500 · Current $30,000

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:    a) On or about July 22, 2013, the employer failed to assure that approval was obtained by the manufacturer before adding a working platform to a Caterpillar forklift (model C6000 LP; s/n AT83F20144).  The addition was used in the ACO building to lift maintenance workers.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $38,500 · Current $10,000 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:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, the employer failed to develop, document, and utilize energy control procedures to control hazardous energy of the robot associated with Cell #1.  Employees were exposed to crush/struck-by hazards in that energy control was not utilized before employees entered the robot cell to troubleshoot and adjust mechanisms that sense part containers.    Reliable Castings Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(c)(4)(i), which was contained in OSHA Inspection Number 886283, citation number1,  item number 1a and was affirmed as a final order on June 4, 2013, with respect to a workplace located at 1521 W. Michigan St. in Sidney, Ohio.

Issued

Dec 19, 2013

Abate by

Dec 23, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(2): The machine or equipment was not turned off or shut down using the procedures established for the machine or equipment:    a) Reliable Castings Corporation - Sidney, Ohio: On or about July 22, 2013, employees were exposed to injuries associated with crush/struck-by hazards while servicing limit switches that detect the presence of part containers.  The employer failed to assure the equipment was shut down and energy control application steps were followed prior to employees entering the hazard area to service the switches associated with the Cell #1 robot.     Reliable Castings Corporation was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.147(d)(2), which was contained in OSHA Inspection Number 886283, citation number1,  item number 1a and was affirmed as a final order on June 4, 2013, with respect to a workplace located at 1521 W. Michigan St. in Sidney, Ohio.

Issued

Dec 19, 2013

Abate by

Jan 2, 2015

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.132(d)(2): The employer did not verify, through a written certification, the identity of the workplace evaluated, the person certifying that the evaluation had been performed, and the date the hazard assessment was done:    a) Reliable Castings Corporation - Sidney, Ohio: On or about August 13, 2013, the employer did not provide a written certification that identifies the person certifying a workplace evaluation was performed and the date of the hazard assessment.  Employees operating production cells and tending furnaces in the ACO building were exposed to burn injuries associated with molten aluminum metal.

Issued

Oct 10, 2013

Abate by

Dec 16, 2014

Penalty

Initial $60,500 · Current $30,000 Reduced

General-duty citation text

29 CFR 1926.501(b)(10): Each employee engaged in roofing activities on low-slope roofs with unprotected sides and edges 6 feet or more above lower levels, was not protected from falling by guardrail systems, safety net systems, personal fall arrest systems, or a combination of warning line system and guardrail system, warning line system and safety net system, or warning line system and personal fall arrest system, or warning line system and safety monitoring system.      a) Reliable Castings Corp. - Sidney, Ohio: On or about April 16, 2013, the employer failed to assure employees were protected from falls of approximately ten feet, and up to approximately 15 feet, when accessing the roof of the heat treat area to perform a roof repair.