OSHA Inspection: TENNECO AUTOMOTIVE OPERATING COMPANY, INC.

Issued

Nov 13, 2014

Abate by

Aug 1, 2015

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1): The employer did not furnish employment and a place of employment which was free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed to struck-by and crushed-by hazards:    On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA:  Employees were exposed to struck-by and crushing hazards due to the pallet rack system supports being visibly damaged:    a.  at the spring storage rack system area.    b.  the rack system with the blue uprights and orange shelving at the Department 12 blank tube storage area.    c.  the orange rack system with the red painted upright at the Department 12 blank tube storage area.     d.  the orange rack system positioned to the right, at the Department 12 blank tube storage area.     e.  at the Department 76 storage rack system area, Row "A".    f.  at the Department 76 storage rack system area, Row "B".    g.  at the Department 76 storage rack system area, Row "C".    h.  at the Department 19 Shipping storage rack system area, near shelving 179.    i.  at the Department 19 Shipping storage rack system area, near shelving 189.    j.  at the Department 19 Shipping storage rack system area, near shelving 20.    k.  at the Paint & Pack rack system area.    l.  at the Warranty Collection rack system area.    In accordance with 29 CFR 1903.19(d), abatement certification is required for this violation (using the CERTIFICATION OF CORRECTIVE ACTION WORKSHEET), and in addition, documentation demonstrating that abatement is complete must be included with your certification.  This documentation may include, but is not limited to, evidence of the purchase or repair of the equipment, photographic or video evidence of abatement, or other written records.

Issued

Nov 13, 2014

Penalty

Initial $4,400 · Current $3,080 Reduced

General-duty citation text

29 CFR 1910.37(b)(6): Each exit sign was not illuminated to a surface value of at least five foot-candles (54 lux) by a reliable light source and be distinctive in color:    On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA:  Employees were exposed to smoke inhalation and fire hazards where:    a. by the shock bushing assembly line, the lighted directional exit sign over the aisle way was inoperative.    b. by the FIV machine, the lighted exit sign over the door was inoperative.

Issued

Nov 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.37(b)(2): Each exit was not clearly visible and marked by a sign reading "Exit":  On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA: in the pickle house area, the emergency EXIT was not clearly visible in that a sign reading EXIT had not been installed over the emergency exit door.  Employees were exposed to smoke inhalation and fire hazards.

Issued

Nov 13, 2014

Abate by

Dec 3, 2014

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.101(b): The in-plant handling, storage, and utilization of all compressed gases in cylinders, portable tanks, rail tankcars, or motor vehicle cargo tanks were not in accordance with Compressed Gas Association Pamphlet P-1-1965, which is incorporated by reference as specified in CFR 1910.6:  On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA, in the cylinder storage area on the pad:  a.  powered industrial trucks are driven within approximately three feet of stored full cylinders of compressed oxygen, argon, acetylene, and empty cylinders of oxygen and argon, to perform propane tank changes and fillings on a daily basis.  The compressed gas cylinders are not protected from damage.  b.  an empty argon cylinder was stored without a cap.

Issued

Nov 13, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.253(b)(2)(iv): Valve protection caps, where cylinders were designed to accept caps, were not always in place, hand-tight, except when cylinders were in use or connected for use:   On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA:  in the cylinder storage area on the pad an empty oxygen cylinder was stored without a cap.

Issued

Nov 13, 2014

Abate by

Jan 2, 2015

Penalty

Initial $7,000 · Current $4,900 Reduced

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 5/14/2014 at 200 McIntyre Drive, Hartwell, GA:    a.  at the MTS servo tester, specific procedural steps for isolating and blocking equipment during lockout included locking out the servo tester prior to making any changes to the proximity switches that did not exist on this piece of equipment.

Issued

Nov 13, 2014

Penalty

Initial $0 · Current $2,310

General-duty citation text

29 CFR 1910.157(e)(3): Portable fire extinguishers were not subjected to an annual maintenance check:    On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA, where employees are required to fight incipient level fires portable fire extinguishers were not subject to an annual maintenance check:    a.  near the pickle house compressed air station, the annual inspection was due on 5/8/2014.     b.  in the mechanics shop, tube side, the annual inspection was due on 8/6/2013.

Issued

Nov 13, 2014

Abate by

Aug 1, 2015

Penalty

Initial $5,500 · Current $3,850 Reduced

General-duty citation text

29 CFR 1910.176(b): Storage of material created a hazard:    On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA:   employees were exposed to falling objects where the rack system or used pallets did not  adequately support the placed load:    a.  in department 76 storage.    b.  in department 19 storage.    c.  in the Paint & pack storage area.

Issued

Nov 13, 2014

Penalty

Initial $3,300 · Current $2,310 Reduced

General-duty citation text

Section 5(a)(1) of the Occupational Safety and Health Act of 1970:  The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that, employees were exposed to struck-by hazards from falling loads:    On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA, in the maintenance fabrication shop, the material handling hook used at the hoist was missing the safety latch where it was designed to have such a latch.

Issued

Nov 13, 2014

Abate by

Apr 4, 2015

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

OSH ACT of 1970 Section (5)(a)(1):     The employer did not furnish employment and a place of employment which was free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that employees were exposed hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks:    On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA: throughout the facility, employees were exposed to struck-by and crushed-by hazards where the pallet tippers were not guarded.

Issued

Nov 13, 2014

Abate by

Dec 9, 2014

Penalty

Initial $7,000 · Current $4,900 Reduced

General-duty citation text

29 CFR 1910.212(b): Machine(s) designed for fixed location(s) were not securely anchored to prevent walking or moving:      On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA:  machinery including, but not limited to the following was not permanently affixed to the floor:      a.  in the prototype shop, the Dake hydraulic press, model 50 H, MAECO 11106, s/n 185851.      b.  in the prototype shop, the Baldor grinder, s/n F389.      c.  in the prototype shop, the Baldor grinder, s/n F1188.      d.  in the prototype shop, the Clausing drill press, MAECO 10774.

Issued

Nov 13, 2014

Abate by

Nov 25, 2014

Penalty

Initial $6,600 · Current $4,620 Reduced

General-duty citation text

29 CFR 1910.215(a)(4): Work rest(s) on grinding machinery were not adjusted closely to the wheel with a maximum opening of one eighth inch:    On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA, where employees perform grinding operations:    a.  in the tubing department mechanics shop, the distance between the right work rest and stone of the Baldor grinder was measured at one half inch.    b.  in the tubing department mechanics shop, the distance between the left work rest and stone of the Baldor grinder was measured at one half inch.    c.  in the rework shop, the distance between the work rest and the stone of the Dayton grinder measured at one half inch.

Issued

Nov 13, 2014

Abate by

Nov 25, 2014

Penalty

Initial $5,500 · Current $3,850 Reduced

General-duty citation text

29 CFR 1910.303(g)(1): Sufficient access and working space was not provided and maintained about all electric equipment (operating at 600 volts, nominal, or less to ground) to permit ready and safe operation and maintenance of such equipment:    On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA, at the MTS machine in Quality, the lockout point on the electrical box was blocked by the workbench.

Issued

Nov 13, 2014

Abate by

Jan 2, 2015

Penalty

Initial $38,500 · Current $26,950 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:    On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA:     a.  at the "A" line RWC, welding head "C", an operator was observed reaching into the operating machine beyond the pull stop, to toggle the hydraulic ram at changeover.  Employees were exposed to coming in contact with moving parts during changeover tasks, in that lockout/tag out procedures were not utilized.    b. at the "A" line RWC, welding head "B"; operators were   required to reach into the operating machine beyond the pull stop, to toggle the hydraulic ram at changeover.  Employees were exposed to coming in contact with moving parts during changeover tasks, in that lockout/tag out procedures were not utilized.    c.  at the "A" line RWC, welding head "A"; operators are required to reach into the operating machine, beyond the pull stop, to toggle the hydraulic ram at changeover.  Employees were exposed to coming in contact with moving parts during changeover tasks, in that lockout/tag out procedures were not utilized.    d.  at the RWC line, the energy control procedure was not utilized for the task of removing rejects.     Tenneco was previously cited for a violation of this occupational safety and health standard or its equivalent standard (1910.147(c)(4)(i), which was contained in OSHA inspection number 315740639, citation number 1, item number 1 and was affirmed as a final order on 9/20/2012, with respect to a workplace located at 200 McIntyre Drive, Hartwell, GA.

Issued

Nov 13, 2014

Abate by

Dec 3, 2014

Penalty

Initial $550 · Current $5,285

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 6/4/2014, an employee was observed performing maintenance on the welder that was locked out but was not identified with his name as controlling the lock.    Tenneco was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.147(c)(5)(ii)(D), which was contained in OSHA inspection number 523498, citation number 2, item number 1 and was affirmed as a final order on 11/14/2012, with respect to a workplace located at 200 McIntyre Drive, Hartwell, GA.

Issued

Nov 13, 2014

Penalty

Initial $38,500 · Current $26,950 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:      On or about 5/14/2014 at 200 McIntyre Drive, Hartwell, GA:     a.  at the Marvel horizontal band saw in the Prototype Department, an employee was exposed to amputation hazards where two and one half inches of the unused portion of the bandsaw blade was not guarded.      b.  at the Kalamazoo horizontal band saw in Department 81, an employee was exposed to amputation hazards where the unused portion of the blade was unguarded.      c. at the Hyd-mech, S-20 horizontal band saw in the mechanics shop, employees were exposed to amputation hazards where the unused portion of the blade was not guarded.      Tenneco was previously cited for a violation of this occupational safety and health standard or its equivalent standard  1910.212(a)(1), which was contained in OSHA inspection number 782881, citation number 1, item number 4 and was affirmed as a final order on 5/30/2013, with respect to a workplace located at 200 McIntyre Drive, Hartwell, GA.

Issued

Nov 13, 2014

Abate by

Dec 3, 2014

Penalty

Initial $38,500 · Current $26,950 Reduced

General-duty citation text

29 CFR 1910.215(b)(9): The distance between the abrasive wheel periphery(s) and the adjustable tongue or the end of the safety guard peripheral member at the top exceeded one fourth inch:  On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA:  a.  in the tubing department maintenance shop, employees were exposed to struck-by hazards where the left tongue guard of the Baldor grinder, s/n 70404067024, was opened to the maximum opening of one and seven eighths inches.  b.  in the tubing department maintenance shop, employees were exposed to struck-by hazards where the right tongue guard of the Baldor grinder, s/n 70404067024, was opened to one and three eighths inches.  c. in the rework department, employees were exposed to struck-by hazards where the right tongue guard of the Dayton grinder, MAECO # 22-4BG, was opened to approximately three quarter inches to include the center depth of the worn stone.  Tenneco was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.215(b)(9), which was contained in OSHA inspection number 316017649, citation number, 1 item number 1 and was affirmed as a final order on 2/6/2012, with respect to a workplace located at 121 Meridian Ave, Cozad, Nebraska.

Issued

Nov 13, 2014

Abate by

Dec 10, 2014

Penalty

Initial $33,000 · Current $23,100 Reduced

General-duty citation text

29 CFR 1910.242(b): Compressed air used for cleaning purposes was not reduced to less than 30 PSI:       On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA:     a.  at the RWC machine, employees were performing cleaning operations of machinery with compressed air and were exposed to being struck by flying metal pieces.  Readouts taken from the compressors showed output to be modulated between 85 PSI and 102 PSI at all times.      Tenneco was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.242(b), which was contained in OSHA inspection number 782881, citation number 2, item number 1 and was affirmed as a final order on 05/30/2013, with respect to a workplace located at 200 McIntyre Drive, Hartwell, GA.

Issued

Nov 13, 2014

Penalty

Initial $27,500 · Current $19,250 Reduced

General-duty citation text

29 CFR 1910.253(b)(4)(iii): Oxygen cylinders in storage were not separated from fuel-gas cylinders or combustible materials (especially oil or grease), a minimum distance of 20 feet (6.1 m) or by a noncombustible barrier at least 5 feet (1.5 m) high having a fire-resistance rating of at least one half-hour:     On or about 5/14/14 at 200 McIntyre Drive, Hartwell, GA, in the cylinder storage area on the pad; where oxygen and acetylene were stored within twenty feet:    a. An empty oxygen cylinder stored within 20 feet of the full acetylene bottles, the propane filling station and stored propane tanks.    Tenneco Automotive Operating Company, Inc. was previously cited for a violation of this occupational safety and health standard or its equivalent standard 1910.253(b)(4)(iii), which was contained in OSHA inspection number 312530272, citation number 1, item number 3 and was affirmed as a final order on 2/8/2010, with respect to a workplace located at 200 McIntyre Drive, Hartwell, GA.

Issued

Nov 13, 2014

Abate by

Dec 3, 2014

Penalty

Initial $0 · Current $0

General-duty citation text

29 CFR 1910.147(c)(5)(ii): Lockout devices and tagout devices were utilized for other purposes than controlling energy:  On or about 6/4/2014 at 200 McIntyre Drive, Hartwell, GA, locks designed to be utilized for performing lockout of energy sources was observed being used as follows:  a.  connected to a chain at the forklift battery charging station.   b.  connected to a personal locker in the maintenance shop.  c.  locking a personal locker in the maintenance shop.  d.  locking metal drawers in the maintenance shop; and   e.  securing a broom to the wall in the maintenance shop.