OSHA Inspection: KELLY FOUNDRY & MACHINE COMPANY, INC.

Issued

2014-09-30 00:00:00

Abate by

2014-11-18 00:00:00

Penalty

Initial $1600.00 · Current $1600.00

Hazardous substances 8111

General-duty citation text

29 CFR 1910.95(g)(1):  The employer did not establish and maintain an audiometric testing program as provided in this paragraph by making audiometric testing available to all employees whose exposures equal or exceed an 8-hour time-weighted average of 85 decibels.     (a)  Shake Out and Pouring Deck:  An employee conducting activities such as working on the pouring deck and round table was exposed to occupational noise at 83.26% of the permissible daily noise exposure (eight hour time weighted average of 90 dBA at the 80 dB criterion level) during the 476 minute sampling period on August 14, 2014.  For a full eight hour shift this would be equivalent to an average sound level of 88.6 dBA.  The employer has not instituted and maintained an audiometric testing program for all employees exposed at or above 8 hour time weighted average of 85 decibels, as determined on August 14, 2014.    (b)  Molding Area:  An employee conducting molding activities was exposed to occupational noise at 101.7% of the permissible daily noise exposure (eight hour time weighted average of 90 dBA at the 80 dB criterion level) during the 464 minute sampling period on August 14, 2014.  For a full eight hour shift this would be equivalent to an average sound level of 90.1 dBA.  The employer has not instituted and maintained an audiometric testing program for all employees exposed at or above 8 hour time weighted average of 85 decibels, as determined on August 14, 2014.     Abatement Certification Required for this Item.

Issued

2014-09-30 00:00:00

Abate by

2014-11-18 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 8111

General-duty citation text

29 CFR 1910.95(k)(1): The employer did not train each employee who is exposed to noise at or above an 8-hour time-weighted average of 85 decibels in accordance with the requirements of 29 CFR 1910.95(k). The employer did not institute a training program and ensure employee participation in the program:  (a)  Shake Out and Pouring Deck:  An employee conducting activities such as working on the pouring deck and round table was exposed to occupational noise at 83.26% of the permissible daily noise exposure (eight hour time weighted average of 90 dBA at the 80 dB criterion level) during the 476 minute sampling period on August 14, 2014.  For a full eight hour shift this would be equivalent to an average sound level of 88.6 dBA.   The employer has not instituted a training program and trained employees on occupational noise for all employees exposed at or above 8 hour time weighted average of 85 decibels, as determined on August 14, 2014.    (b)  Molding Area:  An employee conducting molding activities was exposed to occupational noise at 101.7% of the permissible daily noise exposure (eight hour time weighted average of 90 dBA at the 80 dB criterion level) during the 464 minute sampling period on August 14, 2014.  For a full eight hour shift this would be equivalent to an average sound level of 90.1 dBA.  The employer has not instituted a training program and trained employees on occupational noise for all employees exposed at or above 8 hour time weighted average of 85 decibels, as determined on August 14, 2014.    Abatement Certification Required for this Item.     Abatement Note:  Employer must establish a training program that consists of the following: 1.   Effects of noise on hearing, 2.   The purpose of hearing protectors, the advantages, disadvantages, and attenuation various types, and instructions on selection, fitting, use, and care, 3.   The purpose of audiometric testing, and an explanation of the test procedures.    The training program shall be conducted annually for each employee and shall be updated to be consistent with changes in protective equipment and work processes.    Abatement Certification Required for this Item.

Issued

2014-09-30 00:00:00

Penalty

Initial $1200.00 · Current $1200.00

General-duty citation text

29 CFR 1910.178(q)(1): Any power-operated industrial truck not in safe operating condition was not taken out of service, and/or repairs were not made by authorized personnel:  (a)  Shipping and Receiving Area:  An employee operates a Clark C25L forklift that was not equipped with an operable backup alarm.  The forklift was not taken out of service until an operable backup alarm could be installed, as determined on August 14, 2014.

Issued

2014-09-30 00:00:00

Penalty

Initial $1200.00 · Current $1200.00

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:  (a)  Molding Area:  Employees operated a Queen City Machine Tool Co. abrasive pedestal grinder that had a maximum opening of 3/4 of an inch from the grinding wheel and tool rest,  as determined on August 14, 2014.

Issued

2014-09-30 00:00:00

Penalty

Initial $0.00 · Current $0.00

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:                                                                                      (a)  Molding Area:  Employees operated a Queen City Machine Tool Co. abrasive pedestal grinder that had a maximum opening of 2 and 1/2  inches from the grinding wheel and the end of the safety guard peripheral member, as determined on August 14, 2014.

Issued

2014-09-30 00:00:00

Abate by

2014-11-18 00:00:00

Penalty

Initial $2800.00 · Current $2800.00

Hazardous substances 0731

General-duty citation text

29 CFR 1910.1000(a)(2): Employee(s) were exposed to an airborne concentration of copper fume/dust listed in Table Z-1 in excess of the 8 hour Time Weighted Average concentration of 0.100 micrograms per cubic meter:  (a)  Grinding Area:  An employee conducted grinding on cast iron parts was exposed to copper fume/dust at an airborne concentration of 0.1200 micrograms per cubic meter of air for an 8-hour time weighted average, as determined on September 19, 2014.  Abatement Certification and Documentation Required for this Item.

Issued

2014-09-30 00:00:00

Abate by

2015-02-17 00:00:00

Penalty

Initial $0.00 · Current $0.00

Hazardous substances 0731

General-duty citation text

29 CFR 1910.1000(e): Feasible administrative or engineering controls were not determined and implemented to achieve compliance with the limits prescribed in 29 CFR 1910.1000(a) through (d):  (a)  Grinding Area:  An employee conducting grinding on cast iron parts was exposed to copper fume/dust at an 8-hour Time Weighted Average of 0.1200 micrograms per cubic meter of air for the 446 minute sampling period on August 14, 2014.  The employer has not implemented all feasible engineering or administrative controls to achieve compliance with the permissible exposure limit of 0.100 micrograms per cubic meter, as determined on September 19, 2014.    Feasible engineering/administrative controls include, but are not limited to the following:    1. Increase the suction on the local exhaust ventilation at the grinder.      2.  Repair the damaged duct work for the local exhaust ventilation system; such as removing dents and patching holes, to increase the ventilation system efficiency.     3.  Installing a different type of capture hood at the grinder to increase the capture efficiency of the local exhaust ventilation system.        Step 1:  Effective respiratory protection shall be provided and used by exposed employees as an interim protective until feasible engineering and/or administrative controls can be implemented, or whenever such controls fail to reduce employee exposure to within permissible exposure limits.  Step 2:  Submit to the Area Director a written, detailed plan of abatement outlining a schedule for the implementation of engineering and/or administrative measures to control employee exposure to hazardous substances as referenced in this citation.  The plan shall include, at a minimum, target dates for the following actions which must be consistent with the abatement dates required by this citation:    (1)    Evaluation of engineering/administrative control options; (2)    Selection of optimum control methods and completion of design; (3)    Procurement, installation and operation of selected control measures; and (4)    Testing and acceptance or modification redesign of controls.    Note:  All proposed control measures shall be approved for each particular use by a competent industrial hygienist or other technically qualified person.    Step 3:  Abatement shall have been completed by the implementation of feasible engineering and/or administrative controls upon verification of their effectiveness in achieving compliance.     Abatement Certification and Documentation Required for this Item.

Issued

2014-09-30 00:00:00

Abate by

2014-10-27 00:00:00

Penalty

Initial $1600.00 · Current $1600.00

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 Wide:  The employer has not provided employee with training on the hazardous chemicals used in the work area such as but not limited to, silica in the sand during molding and metal fumes during metal heating, metal pouring, and metal grinding, as determined August 14, 2014.   Abatement Note:  Training must meet the requirements set forth in 29 CFR 1910.1200(h)(3).  Abatement Certification Required for this Item.

Issued

2014-09-30 00:00:00

Abate by

2014-10-20 00:00:00

Penalty

Initial $0.00 · Current $0.00

General-duty citation text

29 CFR 1910.134(k)(6): The employer did not provide the basic advisory information on respirators, as presented in Appendix D of 29 CFR 1910.134, in written or oral format to employees who wear respirators when such use was not required by the employer:  (a) Shakeout:  Employees voluntarily wear Moldex 2200 N95 filter facepieces while working at the round table during shakeout.  The employer has not provided employees with the information in Appendix D of 29 CFR 1910.134, as determined on August 14, 2014.  Abatement Certification Required for this Item.