OSHA Inspection: ALC MANUFACTURING, INC.

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.106(e)(2)(ii)(b)(2): The quantity of Category 2, 3 or 4 flammable liquid located outside of an inside storage room or storage cabinet in a building or in any one fire area of a building exceeded 120 gallons:    a) Paint Shop - On or about 02/28/14 the paint storage room contained flammable materials including (but not limited to) toners, reducers, and waste thinner in excess of 269 gallons.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.106(e)(6)(ii): Category 1 or 2 flammable liquids, or Category 3 flammable liquids with a flashpoint below 100 °F (37.8 °C), were dispensed into containers without the nozzle and container being electrically interconnected.    a) Paint Shop - On or about 02/28/14 employees utilized thinner to clean spraying equipment. The discharging nozzles and the receiving containers were not bonded to prevent the ignition of vapors.    b) Hydrographics Shop - On or about 02/28/14 employees operated the solvent purifier for recycling thinner. The discharging nozzles and the receiving containers were not bonded to prevent the ignition of vapors. (55 gallon drums and 5 gallon pails).      In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Jul 18, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.106(e)(7)(i)(b): Locations where flammable vapor-air mixtures may exist under normal operations were not  classified as Class I, Division 1 according to the requirements of subpart S of this part.     a) Paint Shop - On or about 02/28/14 workers mixed and transferred flammable materials including (but not limited to) toners, reducers, and thinner. The microwave oven, refrigerator, wall outlets, switches, conduits, and light fixtures were not explosion proof.    b) Hydrographics Shop - On or about 02/28/14  the 5A2 Activator (flammable) was sprayed on top of the water surface in the transfer tank. The light fixtures, conduits, switches, disconnect boxes, and wall outlets were not explosion proof.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

May 29, 2014

Penalty

Initial $3,500 · Current $1,000 Reduced

General-duty citation text

29 CFR 1910.107(b)(5)(i): The spraying operations were not designed, installed and maintained such that the average air velocity over the open face of the booth (or booth cross section during spraying operations) was not less than 100 linear feet per minute.     a) Hydrographics Shop - On or about 02/28/14 employees sprayed flammable solvent-based clear coatings on hydrographic prints inside the SprayBake spray booth. The air velocity did not exceed 10 ft./min. (Measurement conducted with Alnor velometer).    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.107(c)(6): Electrical wiring and equipment not subject to deposits of combustible residues but located in a spraying area as herein defined were not explosion-proof type approved for Class I, group D locations and did not otherwise conform to the provisions of subpart S of this part, for Class I, Division 1, Hazardous Locations:    b) Hydrographics Shop - On or about 02/28/14 employees sprayed flammable solvent-based primers on car parts inside the spray room (spray area). The electrical fixtures, conduits, junction boxes and switches were not explosion-proof.     In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

May 29, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

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) Paint Shop - On or about 02/28/14 employees spray-painted flammable solvent-based coatings on car parts, and wore half face cartridge respirators. The employer did not establish and implement a written respiratory protection program.    b) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based clear coatings inside the SprayBake spray booth, and wore half face respirators. The employer did not establish and implement a written respiratory protection program.    c) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based primers inside a spray area, and wore half face respirators. The employer did not establish and implement a written respiratory protection program.       In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

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) Paint Shop - On or about 02/28/14 employees spray-painted flammable solvent-based coatings on car parts, and wore half face respirators. The employer did not provide medical questionnaires to determine the ability of workers to wear the selected respiratory protection equipment.  b) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based clear coatings inside a spray booth, and wore half face respirators. The employer did not provide medical questionnaires to determine the ability of workers to wear the selected respiratory protection equipment.  c) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based primers inside a spray area, and wore half face respirators. The employer did not provide medical questionnaires to determine the ability of workers to wear the selected respiratory protection equipment.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

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) Paint Shop - On or about 02/28/14 employees spray-painted flammable solvent-based coatings on car parts, and wore half face respirators. The employer did not provide fit-testing to ensure that workers were protected.   b) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based clear coatings inside a spray booth, and wore half face respirators. The employer did not provide fit-testing to ensure that workers were protected.   c) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based primers inside a spray area, and wore half face respirators. The employer did not provide fit-testing to ensure that workers were protected.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

May 29, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.134(k)(1): The employer did not provide respirator training to ensure that each employee would be able to demonstrate knowledge of items (i) to ((vii) in this paragraph:    a) Paint Shop - On or about 02/28/14 employees spray-painted flammable solvent-based coatings on car parts, and wore half face respirators. The employer did not provide training in relation to the selection, use, care, and limitations of respiratory protection equipment.      b) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based clear coatings inside a spray booth, and wore half face respirators. The employer did not provide training in relation to the selection, use, care, and limitations of respiratory protection equipment.      c) Hydrographics Shop - On or about 02/28/14 employees spray-painted flammable solvent-based primers inside a spray area, and wore half face respirators. The employer did not provide training in relation to the selection, use, care, and limitations of respiratory protection equipment.      In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $2,800 · Current $1,680 Reduced

General-duty citation text

29 CFR 1910.178(l)(1)(i): The employer did not ensure that each powered industrial truck operator was competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l):    a) Warehouse - On or about 02/28/14 employees operated the Nissan 50 LPG-powered forklift, and the employer did not provide training and evaluation to ensure the safe operation of the vehicles.      In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $2,800 · Current $1,680 Reduced

General-duty citation text

29 CFR 1910.305(a)(2)(ix): All lamps for general illumination were not protected from accidental contact or breakage by a suitable fixture or lampholder with a guard.     a) Paint Shop - On or about 02/28/14 the 8.0 ft. long fluorescent light fixtures inside the storage room were mounted on the walls at a height of 4.5 ft. and were not guarded.     In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET),

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $3,500 · Current $2,100 Reduced

General-duty citation text

29 CFR 1910.305(b)(1)(ii): Unused openings in boxes, cabinets, or fittings were not effectively closed:    a) Detailing Shop - On or about 02/28/14 the dead front panel for the lights, wall outlets and appliances inside the room had an unused opening, exposing workers to live parts.     In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $2,100 · Current $1,260 Reduced

General-duty citation text

29 CFR 1910.1200(e)(1): The employer did not develop, implement, and/or maintain at the workplace a written hazard communication program which describes how the criteria specified in 29 CFR 1910.1200(f), (g), and (h) will be met:    a) Facility - On or about 02/28/14 employees dedicated to the assembly of vehicle parts, spray coating operations, and application of hydrographic prints came in contact with chemicals including (but not limited to) lubricants, flammable solvent-based spray paints in aerosol, upholstery cement, liquefied petroleum gas (LPG), flammable solvent-based primers, coatings, toners, reducers, paint thinner, and flammable activators for hydrographic print processes.  The employer did not develop and implement a written Hazard Communication Program to protect and inform the workers.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.1200(g)(1): Employers did not have a safety data sheet in the workplace for each hazardous chemical which they use:  a) Facility - On or about 02/28/14 employees dedicated to the assembly of vehicle parts, spray coating operations, and application of hydrographic prints came in contact with chemicals including (but not limited to) lubricants, flammable solvent-based spray paints in aerosol, upholstery cement, liquefied petroleum gas (LPG), flammable solvent-based primers, coatings, toners, reducers, paint thinner, and flammable activators for hydrographic print processes.  The employer did not have Safety Data Sheets for the chemicals at the workplace.   In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

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) Facility - On or about 02/28/14 employees dedicated to the assembly of vehicle parts, spray coating operations, and application of hydrographic prints came in contact with chemicals including (but not limited to) lubricants, flammable solvent-based spray paints in aerosol, upholstery cement, liquefied petroleum gas (LPG), flammable solvent-based primers, coatings, toners, reducers, paint thinner, and flammable activators for hydrographic print processes. The employer did train the workers in relation to the Hazard Communication Program, the hazardous properties of the chemicals at the workplace, and the Right to Know.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

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 chemical state and physical form:   Hydrographics Shop - On or about 02/28/14 employees applied Activator 5A2, Product code 643438  (Supplied by Nexeo Solutions) for the water transfer printing process.  The employer did not assess the exposure of employees  to the activator in order to establish if a respiratory protection program was needed for protection of the workers.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

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) Hydrographics Shop - The flexible cables powering the control panels for the Activation Tank and the Rinsing Tank were stapled to the ceiling and were not installed permanently inside conduits.  b) Hydrographics Shop - The flexible cable powering the 20.0 in. diameter air extractor was not installed permanently inside a conduit.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).

Issued

Mar 27, 2014

Abate by

Apr 29, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.305(g)(2)(iii): Flexible cords were not connected to devices and fittings so that tension would not be transmitted to joints or terminal screws:  a) Hydrographics Shop - On or about 02/28/14 the power cable for the 20 in. diameter air extractor had a damaged strain relief device at the male plug. The outer jacket was withdrawn, and the internal conductors and terminals were subjected to strain. The area was covered with masking tape.  In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET).