OSHA Inspection: PLASTIC SYSTEMS, LLC

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $6,930 · Current $6,930

General-duty citation text

29 CFR 1910.147(c)(2)(ii): The employer's tagout energy control program procedures did not successfully comply with 29 CFR 1910.147(c)(3) and no lockout was provided for employee protection:  On or about February 12, 2014, and at times prior thereto, at the B-5 injection-molding machine, Cincinnati-VH-250-29-3902A21/91-24, the employer's tagout system for the electrical disconnect and pneumatic valve did not provide full employee protection. Employees were exposed to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by or electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(3)(i): The tagout device used on an energy isolating device, which was capable of being locked out, was not attached at the same location that the lockout device would have been attached:  On or about February 12, 2014, and at times prior thereto, at the B-5 injection-molding machine, Cincinnati-VH-250-29-3902A21/91-24, tags were not attached at the electrical disconnect nor at the pneumatic valve, which were  capable of being locked out, exposing employees to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by or electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $6,930 · Current $6,930

General-duty citation text

29 CFR 1910.147(c)(5)(ii)(D): Lockout devices and tagout devices did not indicate the identity of the employee applying the device(s):    On or about February 12, 2014, and at times prior thereto, at the injection-molding machine B-5 (Cincinnati-VH-250-29-3902A21/91-24) the tagout devices attached to the busway switch handle rope and the pneumatic air line did not identify the employee applying the tagout devices, exposing employees to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by or electrical hazards.

Issued

Aug 7, 2014

Abate by

Aug 3, 2015

Penalty

Initial $6,930 · Current $6,930

General-duty citation text

29 CFR 1910.147(c)(8): Lockout or tagout was not performed only by the authorized employees who performed the servicing or maintenance:     The employer did not ensure that Lockout or tagout was performed by an authorized employee who performed servicing or maintenance:         a)    On or about February 13, 2014, on Machine A04,      b)    On or about February 13, 2014, on Machine A14,      c)    On or about February 13, 2014 on Machine AA2,      d)    On or about February 18, 2014, on Machine B-1,    Employees were exposed to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by and electrical hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $6,930 · Current $6,930

General-duty citation text

29 CFR 1910.147(d)(1): The authorized employee did not have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy before the authorized or affected employee turned off machine:    On or about February 12, 2014, and at times prior thereto, at the Injection Molding Machine C-0 Toyo 1992 90-Ton, T190G2-1087208, an authorized employee was not knowledgeable of the sources of energy, the hazards, and the methods and means necessary to control all sources of hazardous energy. After attempting to perform lockout, the machine remained energized, exposing the employee to unexpected movement of the machine, caught-between, struck-by and electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 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:    On or about February 12, 2014, and at times prior thereto, at Injection Molding Machine C-0, Toyo 1992 90-Ton, T190G2-1087208, an authorized employee did not perform shutdown and lockout of the machine according to procedures established. The machine remained energized, exposing the employee to unexpected movement of the machine, caught-between, struck-by or electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(d)(3): All energy isolating devices that were needed to control the energy to the machine or equipment were not physically located and operated in such a manner as to isolate the machine or equipment from the energy source(s):    On or about February 12, 2014, and at times prior thereto, at Injection molding machine C-0, Toyo 1992 90 Ton, T190G2-1087208, an authorized person did not locate and operate all energy isolating devices during lockout of this machine.  Verification of lockout resulted in machine movement, exposing the employee to caught-between, struck-by and electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $4,950 · Current $4,950

General-duty citation text

29 CFR 1910.212(a)(1): Machine guarding was not provided to protect operator(s) and other employees from hazards created by in-going nip points, rotating parts, and/or flying chips and sparks:    On or about February 12, 2014, and at times prior thereto, the employer did not provide machine guards to protect the operators and other affected employees in the machine area from hazards such as those created by rotating parts, flying plastic particles and thermal burns.           a)    Injection Molding Machine A-5 (1998 88-Ton TOYO, FN1000/S08T026), purge cover guard was broken.        b)    Injection Molding Machine A-4 (1993 396 Ton Nissei, FS360S100AS/ES36M058), plexi-glass door guard was              broken.        c)    Injection Molding Machine E-6  (1996 400-Ton Engel, ES2000/400AH/7611/400/95), plexi-glass and seal on the              door guard at the operators station was broken         d)    Injection Molding Machine A-4 (1993 396 Ton Nissei, FS360S100AS/ES36M058), injection heat barrel guard              was missing.        e)    Injection Molding Machine C-12 (1997 150-Ton Toyo, TM150H/1140059), injection-heat barrel guard              was missing.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $4,950 · Current $4,950

General-duty citation text

29 CFR 1910.303(b)(1): Electrical equipment was not free from recognized hazards that were likely to cause death or serious physical harm to employees:    On or about February 12, 2014, and at times prior thereto, on the production floor, employees were exposed to electrical hazards in the following instances:        a)    At Injection Molding Machine A-4 (1993 396-Ton Nissei, FS360S100AS/ES36M058),              480V conductors (band heater wiring) was left suspended and not contained just              below the injection barrel exposing employees to electrical hazards.         b)    At Injection Molding Machine A-5 (1997 150-Ton Toyo, TM150H/1140032), 480V              conductors (band heater wiring) was left suspended and not contained just below              the injection barrel exposing employees to electrical hazards.        c)    At Injection Molding Machine C-12 (1997 150-Ton Toyo, TM150H/1140059), 480V              conductors (band heater wiring) left suspended and not contained just below the              injection barrel exposing employees to electrical hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(1)(iv): Electric equipment was not free from recognized hazards that were likely to cause serious physical harm to employees, such as damaged electrical insulation:    On or about February 12, 2014, and at times prior thereto, at Injection Molding Machine A-10 (1996 500-Ton Toyo, TM500G2/1115019), the 120-volt electrical conductor supplying power to the operator's workstation had damaged insulation. Internal conductors were not protected against physical contact and damage at two locations, exposing employees to electrical shock hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $2,970 · Current $2,970

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:    On or about February 12, 2014, and at times prior thereto, on the production floor at Injection Molding Machine E-7 (1999 850-Ton Cincinnati, MH-850-76/H08A0400001), the employer used an extension cord connected to a relocatable power tap, a condition specifically prohibited by the listing and labeling instructions. The cord was used to power the conveyor belt and operators workstation light. Employees were exposed to electrical hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $4,950 · Current $4,950

General-duty citation text

29 CFR 1910.303(b)(8)(i): Electrical equipment was not firmly secured to the surface on which it was mounted:    On or about February 12, 2014, and at times prior thereto, on the production floor, two 480V Sorgel Transformers were not secured to the floor, exposing employees to fire and electrical hazards:      a)    The 480V Transformer Cat No. 45t3H located against the entrance wall was not firmly secured. Movement forced the transformer into the wall not allowing for proper ventilation in accordance with transformer ventilation requirements of National Electrical Code (NEC) Article 450.9, which to provide enough ventilation so the transformer does not overheat by ensuring the openings are not blocked by walls or other obstructions.      b)    The 480V Transformer Cat No. 45t3H located against the entrance wall was not firmly secured. The transformer was pushed approximately within 1-inch of the wall and not allowing for proper ventilation in accordance with transformer ventilation requirements of National Electrical Code (NEC) Article 450.9, which is to provide enough ventilation so the transformer does not overheat by ensuring the openings are not blocked by walls or other obstructions.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $3,960 · Current $3,960

General-duty citation text

29 CFR 1910.305(a)(2)(ix): Lamps for general illumination were not protected from accidental contact or breakage by a suitable fixture or lamp holder with a guard:      On or about February 12, 2014, and at times prior thereto, on the production floor, the fluorescent lighting at operator workstations was not guarded from accidental contact or breakage. The lighting measured 5-feet 8-inches from the floor. Employees were exposed to potential contact hazards in the following instances:          a)    A-10, fluorescent lighting at operator workstation was left unguarded.        b)    A-5, fluorescent lighting at operator workstation was left unguarded.        c)    C-12, fluorescent lighting at operator workstation was left unguarded.        d)    E-6, fluorescent lighting at operator workstation was left unguarded.        e)    E-7, fluorescent lighting at operator workstation was left unguarded.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

CFR 29 1910.305(b)(3)(i): Boxes shall provide a complete enclosure for the contained conductors or cables:    On or about February 12, 2014, and at times prior thereto, on the production floor the circuit breaker boxes against the wall were damaged, employees were exposed to electrical shock and burn hazards in the following instances:          a)    There was damage to 208V circuit breaker box-V; at the bottom, left corner the box was bent in which left an              open gap into the box.        b)    There was damage to 208V circuit breaker box-W; the door would not close completely leaving an open gap at              the bottom.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(j)(1)(i): Fixtures, lampholders, lamps, rosettes, and receptacles located within 8 feet of the floor had live parts exposed to employee contact:    On or about February 12, 2014, and at times prior thereto, on the production floor at Injection Molding Machine C-12 (1997 150-Ton Toyo, TM150H/1140059), the operator's workstation light fixture had exposed live wiring. The light fixture measured 5-feet 8-inches from the floor. Employees were exposed to electrical shock and burn hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $34,650 · Current $34,650

General-duty citation text

29 CFR 1910.147(c)(4)(ii): 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):    On or about February 12, 2014, and at times prior thereto, for injection molding machines including but not limited to 1 - 8, lockout/tagout procedures did not clearly address specific techniques to be utilized for the control of hazardous energy sources associated with each machine. Employees were exposed to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by or electrical shock hazards.      a)      Injection Molding Machine A-4  (1993 396 Ton)                 Nissei        FS360S100AS       ES36M058    b)      Injection Molding Machine A14  (1997 150 Ton)                Toyo                TM150H       1140047    c)      Injection Molding Machine B-1   (1998 231 Ton)                Nissei      FS2210S50ASE       S21G020    d)      Injection Molding Machine C-1   (1992 85 Ton)                  Van Dorn     85-RS-SF-HT      368    e)      Injection Molding Machine E-5   (1996 500 Ton)                Engel      ES2000/500AH       7298/500/95    f)       Injection Molding Machine E-6   (1996 400 Ton)                Engel      ES2000/400AH       7611/400/95    g)      Injection Molding Machine E-7   (1999 850 Ton)                Cincinnati       MH-850-76       H08A0400001    h)      Injection Molding Machine E-9   (1997 600 Ton)                Mitsubishi         610MJ-80       3G508052    Plastic Systems, LLC 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 313499501, citation number 002, item number 001 and was affirmed as a final order on July 13, 2011, with respect to a workplace located at 1305 Henry Brennan, El Paso, TX 79936.      Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.147(c)(4(ii), which was contained in OSHA inspection number 313784613, citation number 001, item number 001a and was affirmed as a final order November 9, 2010, with respect to a workplace located at 13950 US Rte 68 S., Kenton, OH 43326.

Issued

Aug 7, 2014

Abate by

Aug 26, 2014

Penalty

Initial $34,650 · Current $34,650

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:    On or about February 12, 2014, and at times prior thereto, annual periodic inspections of the employer's energy control procedures were not conducted. Documentation provided by the employer indicated last inspections were performed in 2012. Employees were exposed to unexpected energization or startup of the machines or equipment, or release of stored energy causing caught-between, struck-by or electrical shock hazards.      Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.147(c)(6)(i), which was contained in OSHA inspection number 313499501, citation number 002, item number 002 and was affirmed as a final order on July 13, 2011, with respect to a workplace located at 1305 Henry Brennan, El Paso, TX 79936.      Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.147(c)(6)(i), which was contained in OSHA inspection number 313784613, citation number 001, item number 002 and was affirmed as a final order November 9, 2010, with respect to a workplace located at 13950 US Rte 68 S., Kenton, OH 43326.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $13,860 · Current $13,860

General-duty citation text

29 CFR 1910.147(c)(7)(i): The employer did not provide training to ensure that the purpose and function of the energy control program was 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:    On or about February 12, 2014, and at times prior thereto, the employers failure to effectively train employees resulted in the employee(s) not knowing how to identify each potential energy source and isolate those sources during maintenance and servicing operations. Failing to isolate all potential energy sources during maintenance and servicing operations could result in serious injuries such as crush-by, struck-by, impalements, third and fourth degree burns and/or electrical shock hazards.    Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.147(c)(7)(i), which was contained in OSHA inspection number 313784613, citation number 001, item number 003 and was affirmed as a final order on November 9, 2010, with respect to a workplace located at 13950 US Rte 68 S., Kenton, OH 43326.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $9,900 · Current $9,900

General-duty citation text

29 CFR 1910.157(c)(4): Portable fire extinguishers were not maintained in a fully charged and operable condition and kept in their designated places at all times except during use:    On or about February 12, 2014, and at times prior thereto, the employer did not assure that portable fire extinguishers were maintained in a fully charged and operable condition and kept in their designated places at all times. This condition exposed employees to fire hazards.           a)      Near the 50-Ton Engel Injection Molding Machine A-1, located on beam #3, the fire extinguisher was missing.         b)      Near the 500-Ton Toyo Injection Molding Machine A-10, located on beam #4, the Simplex Grinnell 10-               pound ABC Fire Extinguisher was completely discharged and not operable.        c)      Near the 610-Ton Mitsubishi Injection Molding Machine E-8, the Badger 10-pound ABC fire extinguisher was                completely discharged and not operable.    Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.157(c)(4), which was contained in OSHA inspection number 313499501, citation number 001, item number 004a and was affirmed as a final order on July 13, 2011, with respect to a workplace located at 1305 Henry Brennan, El Paso, TX 79936.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $9,900 · Current $9,900

General-duty citation text

29 CFR 1910.157(g)(4): Employees who have been designated to use fire fighting equipment as a part of the emergency action plan were not provided training in the use of appropriate equipment upon initial assignment and at least annually thereafter:    On or about February 12, 2014, and at times prior thereto, the employers failure to effectively train employees resulted in the employee(s) not knowing how to use firefighting equipment as a part of the emergency action plan in the event of a fire. Employees were expected to use portable fire extinguishers to attempt to extinguish fires before evacuating and were exposed to fire hazards.    Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard or its equivalent standard 29 CFR 1910.157(g)(2), which was contained in OSHA inspection number 313499501, citation number 001, item number 004b and was affirmed as a final order on July 13, 2011, with respect to a workplace located at 1305 Henry Brennan, El Paso, TX 79936.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $9,900 · Current $9,900

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords and cables were not connected to devices and fittings so that strain relief is provided that will prevent pull from being directly transmitted to joints and/or terminal screws:    On or about February 12, 2014, and at times prior thereto employees were exposed to electrical shock and burn hazards in the following instances:          a)    On the production floor at the 231-Ton Nissei Injection Molding Machine B-1, Grinder #1002 480V power cable              had strain relief broken at the entry point of the control box.        b)    On the production floor at the 400-Ton Engel Injection Molding Machine E-6, the 120V power cable to              the Conveyor had strain relief broken.        c)    On the production floor at the 400-Ton Engel Injection Molding Machine E-6, the 120V extension              cord connected to the power strip used to power both operator workstation light and conveyor had              strain relief broken.            d)    In the Tool Room, the Vacuum System power cable going into the 240V electrical box had strain relief broken.              There was visible strain to the cable itself, the strain relief fitting had dis-engaged from the cable and box and              had slid half way down the cable.    Plastic Systems, LLC was previously cited for a violation of this occupational safety and health standard 29 CFR 1910.305(g)(2)(iii), which was contained in OSHA inspection number 313499501, citation number 001, item number 008c and was affirmed as a final order on July 13, 2011, with respect to a workplace located at 1305 Henry Brennan, El Paso, TX 79936.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $990 · Current $990

General-duty citation text

29 CFR 1904.32(a)(4): The employer did not post an OSHA 300A Form or equivalent from February 1 to April 30 following the year covered by the form:    On or about February 12, 2014, and at times prior thereto, the employer did not post an OSHA 300A Form or equivalent starting February 1, 2014.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $990 · Current $990

General-duty citation text

29 CFR 1910.157(d)(1): Portable fire extinguishers were not distributed based on the classes of anticipated workplace fires and on the size and degree of hazard that would affect their use:    On or about February 12, 2014, and at times prior thereto, fire extinguishers were not distributed based on the potential  for Class B fires, requiring a travel distance of 50 feet or less. The distance between fire extinguisher at beam #3 and #4 was 59.04-feet. The distance between beam #4 and #5 was 57-feet. There were approximately 120-feet between one fire extinguisher and the next, exposing employees to fire hazards.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.303(b)(7)(iv): There existed damaged parts that could have adversely affected the safe operation or mechanical strength of electrical  equipment, such as parts that are broken or bent:    On or about February 12, 2014, and at times prior thereto, on the production floor, the circuit breaker boxes against the wall were damaged, employees were exposed to fire hazards in the following instances:          a)    There was damage to 208V circuit breaker box-V at the bottom left corner, the box was bent in which left an              open gap into the box.        b)    The latch to 208V circuit breaker box-W door was broken; the door would not close completely leaving an open              gap at the bottom.        c)    The latch to 480V circuit breaker box-FF door was broken; the door would not effectively close.

Issued

Aug 7, 2014

Abate by

Aug 13, 2014

Penalty

Initial $990 · Current $990

General-duty citation text

29 CFR 1910.305(b)(1)(i): Conductors entering cutout boxes, cabinets, or fittings were not protected from abrasion, and openings through which conductors enter were not effectively closed:      On or about February 12, 2014, and at times prior thereto on the production floor, openings through which conductors enter were not effectively closed.  Employees were exposed to electrical shock and burn hazards.          a)    At the 231-Ton Nissei Injection Molding Machine B-1 the Thoreson McCosh Thermal-D Tech II dryer              Model #TD24, Serial #8904118 had an unused opening on the side where a conductor was originally              run through.         b)    The 500-Ton Toyo Injection Molding Machine A-10 had an unused opening on the side where a conductor              was originally run through.